Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
3. Remove the intake manifold plenum.
4. Disconnect the engine fuel pipes at the rail.
5. Remove the engine fuel pipe bracket bolt.
6. Remove the fuel inlet and return line O-rings and discard.
7. Disconnect the injector electrical connector.




8. Remove the fuel rail retaining bolts (1,3,5).
9. Disconnect the vacuum hose line to pressure regulator.
10. Remove the fuel rail (2) from the intake manifold (4).
11. Remove the injector O-ring seal from the spray tip end of each injector. Discard the seals. With the O-ring removed, the O-ring backup may slip off of the injector. Be sure to retain O-ring backup for reuse.

Installation Procedure




1. Install the fuel rail assembly (2) into the intake manifold (4). Tilt the rail assembly to install the injectors.

Notice: Refer to Fastener Notice in Caution and Notices.

2. Install the fuel rail attaching bolts (1,3,5).

Tighten the fuel rail attaching bolts to 10 Nm (89 lb in).

3. Connect the injector electrical connectors.

Important: Ensure that the O-ring backups are on the injectors before installing the new O-rings. Lubricate the new injector O-ring seals with clean engine oil and install on the spray tip end of each injector.


4. Install the new O-rings on the fuel pipes.
5. Connect the fuel feed and return lines. Use a back-up wrench on the fittings to prevent them from turning.

Engine fuel pipe nuts to 27 Nm (20 lb ft).

6. Connect the negative battery cable.
7. Install the fuel filler cap.
8. Use the following procedure to inspect for fuel leaks:

1. Turn the ignition switch to the ON position for 2 seconds.
2. Turn the ignition switch to the OFF position for 10 seconds.
3. Again, turn the ignition switch to the ON position.
4. Inspect for fuel leaks.

9. Install the intake manifold plenum.