Fuel Rail: Service and Repair

REMOVAL

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running.

1. Relieve the fuel system pressure.

2. Disconnect the battery ground cable.

3. Disconnect the vacuum and electrical connections from the engine air cleaner.

Electrical Connectors:

4. Disconnect both of the fuel injection supply manifold electrical connectors.

5. Remove engine air cleaner.

Fuel Pressure Regulator:

6. Disconnect the fuel return hose and vacuum line from the fuel pressure regulator.

Supply Tube Bolt:

7. Remove the fuel supply tube bolt from the fuel Injection supply manifold. Discard both copper crush washers.

Fuel Injector Manifold Connector:

8. Remove the fuel injector manifold connector from the rear side of the fuel injection supply manifold.

Fuel Injection Supply Manifold Bolt Insulators:

9. Remove the two rear (RH) fuel injection supply manifold bolts.

NOTE: A plastic isolator is located under each fuel injection supply manifold bolt. Retain these isolators for installation.

Supply Manifold:

10. Lift slightly, then slide the rear (RH) fuel injection supply manifold toward the LH side of the vehicle to remove.

11. Remove the plastic isolators from their seats.

12. Remove the two forward (LH) fuel injection supply manifold bolts.

13. Lift slightly, then slide the forward (LH) fuel injection supply manifold toward the LH side of the vehicle to remove.

14. Remove the plastic isolators from their seats.

INSTALLATION

To install, reverse the removal procedure, noting the following:

a. Ensure the fuel rail isolators are properly aligned between the fuel rail and the intake manifold.

b. Tighten the fuel injection supply manifold bolts to 19-25 Nm (14-18 lb ft).

c. When Installing the fuel tube, use two new copper crush washers.