Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Remove the air cleaner outlet duct.
3. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail.
4. Cap or plug the fuel line and the fuel rail to prevent contamination.




5. Disconnect the engine harness electrical connector (2) from the fuel injector harness.
6. Remove the fuel injector harness connector clip from the intake manifold.
7. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.




8. Remove the fuel rail bolts.

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

9. Pull the fuel rail back and upward to remove 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. Remove 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 engine harness electrical connector (1) to the MAP sensor.
6. Connect the engine harness electrical connector (2) to the fuel injector harness.
7. Install the fuel injector harness connector clip to the intake manifold.




8. Remove the caps or plugs from the fuel line and the fuel rail.
9. Connect the fuel feed line quick connect fitting (4) to the fuel rail.
10. Connect the negative battery cable.
11. 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.

12. Install the air cleaner outlet duct.