Fuel Rail: Service and Repair

REMOVAL

1. Thoroughly clean the engine.

2. Release pressure from fuel system.

3. Remove the upper intake manifold assembly.

4. Disconnect the fuel supply line fitting at the fuel injection supply manifold.

5. Disconnect the fuel return line from the fuel pressure regulator.

6. Remove six Torx head stud bolts retaining the fuel injection supply manifold and remove the fuel injection supply manifold.

7. Remove the fuel injector nozzle tips from the fuel injection supply manifold and wipe cup clean with a clean, dry cloth.

INSTALLATION

1. Make sure the fuel injector end caps are clean and free of contamination. Inspect fuel injector O-rings. Replace if required.

CAUTION: Do not use silicone grease to lubricate 0-rings. Silicone grease can plug fuel injector nozzle tips.

2. Carefully wipe the fuel injector recesses in the intake manifold and make sure they are free of contamination. Grease the recesses with light grade oil 10W30 ESE-MLC153-E or equivalent.

3. Locate the three fuel injector nozzle tips on the right side recesses of the intake manifold. Then locate the three on the left.

4. Position the fuel injection supply manifold and press down firmly until the fuel injector nozzle tips are fully seated in the fuel injection supply manifold and lower intake manifold. The fuel injection supply manifold should be fully seated on the lower intake manifold.

Fuel Injection Supply Manifold And Related Components:

5. Install the six Torx head stud bolts and tighten to 10-14 Nm (7-10 ft lb).

6. Install the fuel supply line and tighten the fitting to 20-24 Nm (15-18 ft lb).

7. Make sure fuel line is clean. Install the fuel return line to the fuel pressure regulator.

8. Install the upper intake manifold.