Fuel Rail: Service and Repair

Fuel injection supply manifold

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Removal

Removing upper intake manifold
Drain the fuel system. See: Fuel system pressure release Fuel System Pressure Release.
Remove the air cleaner (ACL) module. See: Air filter module Service and Repair.





Caution! Seal the openings in the lower part of the intake manifold with tape or similar.

Remove/loosen the hose clamp for the hose between the intake manifold and the mass air flow sensor.
Remove/loosen the screws, 6 pcs., for the upper intake manifold closest to the front plate and the screws, 2 pcs., opposite the firewall.
Lift up the intake manifold and fold it aside, place it on the battery box.

Draining the fuel system
Unplug the connector for the injectors as well as fuel the pressure sensor in the fuel rail.

Removing the injectors




Blow clean around the injectors.
Remove the fuel rail's attaching bolts. Spray with universal oil or similar around the injectors' connection on the intake manifold.
Pull (without wiggling) loose the fuel rail and injectors. Part the fuel line's quick-coupling by pressing on the 2 blue plastic buttons.
Lift out the fuel rail.

Removing injectors

Remove:
- screws that hold down the mounting rail for the fuel rail
- mounting rail
- the injector.

Installation

Note! For tightening torques, see Specifications. Tightening Torque

Installing injectors
Install the fixing bar in place.
To install the bar the injectors may have to be pulled out a few millimeters from the fuel rail.
Tighten the mounting rail to the fuel rail.

Installing the fuel rail




Press the fuel rail down. Ensure that all injectors locate correctly.
Press together the quick-coupling until you can hear a clicking sound. Bolt down the fuel rail.
Plug in all connectors for the injectors as well as for the fuel pressure sensor.





Caution! Make sure that the guides for the lower section are in the correct position.

Install:
- new gaskets for the upper section of the intake manifold
- the upper intake manifold. Tighten the screws alternately.
Tighten the intake manifold screws. Tighten according to: Tightening torque Tightening Torque.
Tighten the hose clamp to the mass air flow sensor. Connect the connector to the pressure sensor on the intake manifold. Install a new cable tie for the cable harness.

Finishing

Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module. See: Air filter module Service and Repair.

Checking injector
Start the engine and check the function, and check for any leakage.