Fuel Rail: Service and Repair

REMOVAL
1. Release fuel system pressure.
2. Disconnect the negative battery cable, and remove air cleaner to throttle body hose.

Throttle Cable Auto Transaxle:

3. Remove throttle cable and transaxle kickdown linkage.

Throttle Body Connections:

4. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. Remove vacuum hose harness from throttle body, and PCV and brake booster hoses from air intake plenum.

Coolant Temperature Sensor Connections:

5. Remove wiring connector from coolant temperature sensor. Remove EGR tube flange and vacuum connections from intake plenum. Remove fuel hoses from fuel rail.

Plenum Removal:

6. Remove all 8 intake plenum to intake manifold fasteners, and remove plenum from intake manifold. Cover intake manifold ports before proceeding.
7. Disconnect fuel injector harness from engine harness. Remove fuel pressure regulator attaching bolts. Remove fuel pressure regulator from rail. Check fuel pressure regulator O-ring for damage or wear and replace as necessary.
8. Remove fuel rail mounting bolts and lift fuel rail assembly from intake manifold, using care to avoid damaging injectors or injector O-rings.

INSTALLATION
1. Make sure injectors are seated into fuel rail receiver cups, and injector lock clips are in place. Check injector holes to make sure they are clean and any plugs have been removed. Lube injector O-rings with clean engine oil prior to installation.
2. Place the tip of each injector in its respective port and push the rail assembly into place until all injectors are seated in the ports. Install the fuel rail attaching bolts and torque to 13 Nm (115 lb-in).
3. Lube fuel pressure regulator O-ring with clean engine oil, and install fuel pressure regulator onto fuel rail. Install mounting bolts and torque to 8.7 Nm (77 lb-in). Install fuel pressure regulator hoses and clamps and torque to 1 Nm (10 lb-in).
4. Connect fuel injector wiring harness to engine wiring harness, and connect vacuum harness to fuel rail assembly. Remove covering from intake manifold, and clean surface.
5. Place intake manifold gaskets on lower manifold, with beaded sealer up. Install intake plenum and torque fasteners to 13 Nm (115 lb-in).
6. Connect fuel inlet line to fuel rail and torque clamp to 1 Nm (10 lb-in). Connect vacuum harness to air intake plenum and fuel pressure regulator. Connect coolant temperature sensor electrical connector to sensor.
7. Connect brake booster supply hose to intake plenum and connect PCV hose to plenum. Connect AIS motor and TPS, and connect vacuum vapor harness to throttle body.
8. Install throttle cable, and air inlet hose assembly. Connect negative battery cable.
9. Pressurize fuel system and check for leaks. Fuel System Pressurizing Procedure