Fuel Rail: Service and Repair
Fuel Rail AssemblyREMOVAL
NOTE:
- Use care when removing the fuel rail assembly in order to prevent damage to the injector electrical connector terminal and the Injector spray tips.
- Fitting should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passage.
NOTE: An eight-digit identification number is stamped on side of the fuel rail. Refer to this number when you service the fuel rail or when a replacement part is required.
1. Depressurize the fuel system. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the fuel inlet at the rear of the engine.
3. Disconnect the fuel return line at front of the engine.
4. Disconnect the injector electrical connectors.
5. Remove the nuts holding wiring harness onto fuel rail.
6. Remove the bolts retaining fuel rail to the intake manifold.
A. Lift up the injectors carefully to separate them from intake manifold.
B. Lift up the fuel rail with injectors as assembly. Do not separate the fuel injectors from fuel rail.
C. If an injector become separated from fuel rail, injector backup O-ring and injector retainer clip must be replaced.
D. Drain residual fuel from fuel rail into an approved container.
7. If removal of fuel pressure regulator is necessary. Refer to Fuel Pressure Regulator Removal Procedure.
8. If removal of fuel injector is necessary. Refer to Fuel Injectors Removal Procedure.
INSTALLATION
1. Install the fuel injectors if necessary. Refer to Fuel Injector Installation Procedure.
2. Install the fuel pressure regulator if necessary. Refer to Fuel Pressure Regulator Installation Procedure.
3. Place the fuel injector rail assembly on the manifold and insert the injectors into each port by pushing fuel rail.
4. Install two fuel rail retaining bolts. Tighten fuel rail retaining bolts to 19 Nm (14 lb ft)
5. Place wiring harness in its place and secure it with two nuts.
6. Connect electrical connector to each fuel injector.
7. Connect the fuel supply line securely. Do not over tighten.
8. Connect the fuel return line securely. Do not over tighten.
9. Connect the negative battery cable.
10. Crank the engine until it start. Cranking the engine may take longer than usual due to trapped air in the fuel system. Check for leak. If fuel leak is observed, stop engine immediately. Before correct fuel leak, be sure to depressurize system again.