Fuel Rail: Service and Repair

FUEL RAIL

Removal

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

1. Disconnect the battery ground cable.
2. Release the fuel system pressure.
3. Disconnect the fuel tubes.
4. Remove the throttle body (TB).
5. Remove the exhaust gas recirculation (EGR) system module to exhaust manifold tube.
6. Remove the accessory drive belt.







7. Disconnect the generator cable, the electrical connector and the harness pin-type retainer.







8. Remove the bolts and the generator mounting bracket.







9. Separate the fuel charging wiring pin-type retainer from the crash bracket.







10. Disconnect the vacuum tubes and the electrical connector.







11. Remove the bolt and the stud and remove the crash bracket.







12. Disconnect the ground connector from the RH rear stud.







13. Disconnect the generator harness retainer from the LH front stud.







14. Disconnect the eight fuel injector electrical connectors.







15. Remove the crankcase ventilation tube and position out of the way.







16. Disconnect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.







17. Disconnect the two vapor tubes and the electrical connector from the evaporative emission (EVAP) canister purge valve.







18. Remove the four retaining studs (two shown).
19. Remove the fuel rail and the fuel injectors as an assembly.
20. Separate the fuel injectors from the fuel rail.
- Discard the O-ring seals.

Installation

1. CAUTION: Use O-rings seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals.

Lubricate the fuel injectors with clean engine oil and install in the fuel rail.

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







3. Install the fuel rail studs.
- Tighten to 10 Nm (89 lb-in).

4. Install the crash bracket.







5. Install the bolt and the stud.







6. Connect the vacuum tubes and the electrical connector.







7. Install the EVAP canister purge valve electrical connector and the two vapor tubes.







8. Connect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.







9. Connect the crankcase ventilation tube.







10. Connect the eight fuel injector electrical connectors.







11. Install the fuel charging pin-type retainer to the crash bracket.







12. Install the generator mounting bracket and bolts.
- Tighten to 10 Nm (89 lb-in).







13. Connect the generator cable, the electrical connector and the harness pin-type retainer.







14. Connect the ground connector to the RH rear stud.







15. Connect the generator harness location retainer to the LH front stud.
16. Install the accessory drive belt.
17. Install the EGR system module-to-exhaust manifold tube.
18. Install the TB.
19. Connect the fuel tubes.
20. Connect the battery ground cable.