Fuel Rail: Service and Repair

Fuel Rail Assembly Replacement

Removal Procedure

1. Remove the coolant overflow pipe.




2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
3. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe.
4. Remove the fuel rail attaching studs.

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

5. Remove the fuel rail using the following procedure:

1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
2. Rotate the fuel rail in order to position the injectors downward.
3. Remove the fuel rail.

6. Disconnect the fuel injector harness connectors.
7. Remove the fuel injectors.

Installation Procedure




1. Install the fuel injectors.
2. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.

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.

3. Install the fuel rail using the following procedure:

1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
2. Align the injectors by rotating the fuel rail forward.
3. Carefully push the fuel injectors into the cylinder head ports.

Notice: Refer to Fastener Notice.

4. Install the fuel rail attaching studs.

Tighten the fuel rail studs to 10 N.m (89 lb in).

5. Install the fuel supply pipe.

Using a backup wrench on the fuel rail tighten the fuel supply pipe to 14 N.m (10 lb ft).

6. Install the coolant overflow pipe.

Tighten the pipe bolt to 8 N.m (71 lb in).

7. Connect the negative battery cable.
8. 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.