Fuel Rail

FUEL RAIL







Removal
1. Remove the fuel rail supply tube.
2. Remove the fuel injectors.
3. Detach the fuel charging wiring harness from the fuel rail.
4. Remove the bolts and the fuel rail.

Installation

1. NOTE: Lubricate the fuel injector O-ring seal with clean engine oil.

Install a new O-ring seal and a stainless steel combustion gasket on the fuel injector.

2. CAUTION:
- Failure to tighten the fuel injector correctly may lead to engine failure.
- To prevent engine damage, do not use air tools to install the fuel injector. The fuel injector hold-down clamp assembly bolt retainer that extracts the injector may dislodge and fall into the oil drain hole.
- If the fuel injector hold-down clamp assembly bolt retainer is damaged or missing, a new fuel injector hold-down clamp assembly must be installed, or the clamp assembly will not be able to remove the fuel injector.

Install the fuel injectors, the fuel injector hold-down clamps and the bolts.
- Tighten to 2 Nm (18 lb-in).

3. Install the fuel rail and the bolts.
- Tighten hand tight.

4. NOTE: Use a back-up wrench on the fuel injector fittings.

Install the new fuel injector supply tubes.
1 Remove the fuel system caps from the fuel rail and fuel injectors one at a time prior to assembly of each tube.
2 Position the new fuel injector supply tubes (one at a time) between the fuel rail and the fuel injector and fully hand start and seat the fuel injector supply tube fittings onto the fuel rail and fuel injector connectors. Snug the fuel injector supply tube fittings using the inside-out step sequence (the 2 inside tubes then the 2 outside tubes).
- Tighten to 2 Nm (18 lb-in).

3 Tighten the fuel injector hold-down clamp bolt.
- Tighten to 38 Nm (28 lb-ft).

4 Tighten the fuel rail bolts
- Tighten to 31 Nm (23 lb-ft).

5 NOTE: Pre-tighten the fuel injector fittings first, then the fuel rail fittings.

Pre-tighten the fuel injector supply tube fittings.
- Tighten to 12 Nm (106 lb-in).

6 NOTE: Place a visible mark with a permanent marker on the fuel rail and fuel injector threaded connection. Turning the tube fittings one flat of the fitting is equal to 60 degrees.

Final-tighten the fuel injector supply tube fittings.
- Tighten the tube fittings 60 degrees.

5. Attach the fuel charging wiring harness to the fuel rail.
6. Connect the fuel injector and, if disconnected, the fuel rail pressure (FRP) sensor electrical connectors.
7. Install the LH or RH valve cover.
8. Install the fuel rail supply tube.
9. Bleed the high-pressure fuel system.