Fuel Rail: Service and Repair

Fuel Rail Assembly:

REMOVE OR DISCONNECT

NOTE: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

1. Bleed fuel pressure from the fuel system. Refer to Fuel Pressure Release.
2. Clean fuel rail assembly and connections.
3. Fuel feed and return pipes from the fuel rail tubes by squeezing tabs and pulling off the lines.
4. Vacuum line from the pressure regulator.
5. Vacuum line from the throttle body.
6. Ignition coil wires.
7. Injector electrical connectors.
8. Fuel rail hold down bolts or nuts.
9. Fuel rail with equal force on both sides of the rail.

CAUTION:
- When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminates from entering the fuel passages. It is recommended that fittings be capped, and holes plugged during service.
- Care must be taken not to damage or dirty injector tips, the O-rings, and the inlet and the outlet of the fuel rail.
- Compressed air must not be used to internally flush, clean, dry the fuel rail assembly.
- Fuel rail assembly must not be immersed in solvent.

WARNING: To reduce the risk of fire and personal injury that may result from a fuel leak, always install injector O-rings in proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the injector. The O-rings are the same size but are made of different materials.

INSTALL OR CONNECT
1. O-rings must be replaced on all components that are replaced.
2. Lightly oil injector O-rings with clean motor oil.
3. Place rail on manifold assembly and seat injectors by hand.

Tighten
Bolts to 10 Nm (7 lb. ft.).

4. Fuel injector electrical connectors.
5. Fuel feed and return pipes by pushing pipes onto the fuel rail tubes.
6. Vacuum line to pressure regulator.
7. Vacuum line to throttle body.
8. Ignition coil wires.