Fuel Rail: Service and Repair

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FUEL RAIL REMOVAL/INSTALLATION - HYBRID

Removal

WARNING:Do not smoke, or carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING:Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING:Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
1. Release the fuel system pressure. See Service and Repair.

2. Disconnect the battery ground cable. See Battery Disconnect.

3. Disconnect the fuel supply tube-to-fuel quick connect coupling. See - Quick Release Coupling - Double Locking.

4. Disconnect the 4 fuel injector electrical connectors.

5. Remove the nut and position the radio capacitor aside.

6. Detach the 2 pin-type wire harness retainers from the fuel rail.

7. Remove the 2 fuel rail stud bolts.

8. Remove the fuel rail and injectors as an assembly.

9. Remove the 4 fuel injector retainer clips and the 4 fuel injectors.

- Remove and discard the 8 fuel injector O-ring seals.

Installation

CAUTION:Use O-ring seals that are made of fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-rings seals.
NOTE:Install 8 new fuel injector O-ring seals and lubricate them with clean engine oil.
1. Install the 4 fuel injectors and the 4 retainer clips on the fuel rail.

2. Install the fuel rail and injectors as an assembly.

3. Install the 2 fuel rail stud bolts.

- Tighten to 23 Nm {2.3 kgf-m, 17 ft-lbf}.

4. Attach the 2 pin-type wire harness retainers to the fuel rail.

5. Position the radio capacitor and install the nut.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.

6. Connect the 4 fuel injector electrical connectors.

7. Connect the fuel supply tube-to-fuel rail quick connect coupling. See - Quick Release Coupling - Double Locking.

8. Connect the battery ground cable. See Battery Disconnect.