Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Release (With CH 48027) Fuel Pressure Release (Without CH 48027).
2. Remove the air cleaner assembly.
3. Disconnect the fuel feed line quick connect fitting from the fuel rail.




4. Disconnect the evaporative emission (EVAP) purge tube from the intake manifold.




5. Disconnect the fuel injector harness electrical connector (2).
6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.




7. Remove the fuel injector harness electrical connector clips (4 and 5) from the intake manifold.




8. Remove the fuel rail studs.

Important: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

9. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
10. Remove the fuel rail.
11. Remove the fuel injectors, if necessary.

Installation Procedure

Important: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.




1. Install the fuel injectors, if necessary.
2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
3. Carefully push the fuel injectors into the cylinder head ports.

Notice: Refer to Fastener Notice.

4. Install the fuel rail bolts.

Tighten the bolts to 10 N.m (89 lb in).




5. Connect the fuel injector harness electrical connector (2).
6. Connect the MAP sensor electrical connector.




7. Install the fuel injector harness electrical connector clips (4 and 5) to the intake manifold.




8. Connect the EVAP purge tube to the intake manifold.




9. Connect the fuel feed line quick connect fitting to the fuel rail.
10. Install the air cleaner assembly.
11. Connect the negative battery cable.
12. Inspect for fuel leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.