Fuel Rail: Service and Repair

WARNING: This procedure involves working with parts associated with gasoline delivery. Even though the gasoline may be drained from the parts, some gasoline and/or gasoline vapors may remain. Do not smoke or bring parts into an area where an open flame or spark could ignite the gasoline or gasoline vapors. Serious bodily injury may result if gasoline or vapors ignite. When service procedures involve gasoline suitable fire extinguishing equipment should be available in the area.

REMOVAL

Fuel Injection Components:

1. Remove the air intake surge tank.
2. Reduce the internal pressure of the fuel lines and hoses by completing the following operations:

Electric Fuel Pump And Fuel Gauge Connectors:

3. Disconnect the fuel pump harness connector at the rear of the fuel tank.
4. Start and run the engine until it stalls, then turn the ignition switch to OFF.
5. Disconnect the battery negative terminal.
6. Connect the fuel pump harness connector.
7. Disconnect the high pressure fuel line form the fuel rail.

CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the fuel rail or line.

8. Remove the fuel rail mounting bolts.
9. Disconnect the fuel return line from the fuel regulator.

Fuel Rail And Injectors:

10. Remove the fuel rail with the injectors and regulator in position. Being careful not to drop any of the injectors while removing the rail.
11. Remove the injectors from the fuel rail.

NOTE: Fuel may spill out of the fuel rail when the injectors are removed.

INSTALLATION

Fuel Injector Insulators:

1. Install a new insulator to the intake manifold.

Injector Seals:

2. Install a new grommet and O-ring to the injector.
3. Apply a coating of solvent, spindle oil or gasoline to the O-ring of the injector.

Injector Installation:

4. While turning the injector to the left and right, install it on to the fuel rail.
5. Be sure the injector turns smoothly.

NOTE: If it does not turn smoothly, the O-ring may be jammed, remove the injector and re-insert it into the fuel rail. Re-check that the injector turns smoothly.

Fuel Rail Insulator:

6. When installing the fuel rail, check to be sure that the rail insulator is correctly inserted into the installation holes. Tighten the mounting bolts.

Torque: 10 - 13 Nm (7 - 9 lb ft)

Fuel High Pressure Hose Installation:

7. When connecting the high pressure fuel hose to the fuel rail, apply fuel to the hose union, and then insert, being careful not to damage the O-ring.
8. Install the fuel pressure regulator to the fuel rail.
9. After replacement of the fuel rail and injectors, check for leaks with the system pressurized.