Fuel Rail: Service and Repair

Note: In addition to the servicing of the fuel rail, this procedure should be referenced when removing or installing the fuel pressure regulator or fuel injectors.

Fig. 1:

Remove
- Reposition top edge of trunk front liner for access.
- Disconnect multi-plug from evaporative loss flange inset (Fig. 1).
- Switch ignition on.
- Crank engine to depressurize fuel system.
- Switch ignition off.
- Disconnect battery.
- Disconnect earth lead eyelet (1 Fig. 1) from inlet manifold stud.
- Disconnect engine harness to oxygen sensor leads multi-plug.
- Disconnect engine harness to starter motor solenoid link lead multi-plug.
- Undo fuel injector multi-plug cover fixings (2 Fig. 1).
- Disconnect cover from injectors (3 Fig. 1).
- Undo fuel rail to feed pipe union nut (4 Fig. 1).
- Reposition fuel feed pipe from fuel rail union and fit blanking plugs to rail and pipe.
- Undo and remove regulator mounting bracket to inlet manifold bracket securing bolt (5 Fig. 1).
- Undo fuel rail to regulator union nut.
- Reposition regulator from fuel rail union and fit blanking plugs.
- Undo and remove fuel rail securing bolts.

Fig. 2:

- Remove fuel rail assembly (1 Fig. 2) from manifold.
- Fit blanking plugs to manifold.
- Drain the residual fuel from the fuel rail into a suitable drain tin.
- Remove the injector retaining clips (2 Fig. 2).
- Remove injectors (3 Fig. 2).
- Disconnect vacuum hose from regulator.
- Remove regulator mounting bracket.
- Undo fuel rail to regulator union nut.
- Remove regulator assembly.

Refit in the reverse order of the removal procedure.