Fuel Rail: Service and Repair

FUEL RAIL

Part 1:

Part 2:

Exploded View

Removal and Installation

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 can be ignited, resulting in possible personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to do so can result in personal injury.

1. Disconnect the battery ground cable.







2. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.

Remove the engine appearance cover and the noise suppressor (if detached).

3. Remove the air cleaner outlet pipe.
4. Release the fuel system pressure.
5. Remove the 4 engine appearance cover mounting bracket nuts and the brackets.
- To install, tighten to 6 Nm (53 lb-in).

6. Disconnect the fuel pressure sensor electrical connector from the fuel pressure sensor.
7. Disconnect the fuel pressure sensor vacuum connector from the fuel pressure sensor.
8. Disconnect the 8 fuel injector electrical connectors from the fuel injectors.
9. Disconnect the fuel temperature sensor electrical connector from the fuel temperature sensor.
10. Disconnect the fuel supply tube retaining clip from the fuel injection supply manifold.
11. Disconnect the fuel supply tube spring lock coupling.
12. Remove the 4 bolts and the fuel injection supply manifold and fuel injectors as an assembly.
- To install, tighten to 9 Nm (80 lb-in).

13. Remove the 8 fuel injectors from the fuel injection supply manifold.

14. CAUTION: Use O-ring 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 the O-ring seals.

Remove and discard the 16 O-ring seals from the fuel injectors.

15. To install, reverse the removal procedure.
- Lubricate the new fuel injector O-ring seals with clean engine oil before installing.
- Align the fuel tube fittings and press together until an audible click is heard. Then, pull on the fittings to make sure they are fully engaged.