Fuel Rail: Service and Repair

Fuel Rail Assembly Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Remove the air cleaner outlet duct.
3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail.




4. Disconnect the electronic throttle control (ETC) electrical connector.
5. Remove the 2 engine harness clips from the fuel rail tabs.




6. Remove the fuel injector wiring harness electrical connector (1) clip from the intake manifold tab.
7. Disconnect the engine harness electrical connector (2) from the fuel injector harness wiring electrical connector (1).




8. Remove the fuel rail bolts.

Important: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector spray tips.

9. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
10. Remove the fuel rail.






Important: The fuel injector tip insulators may be located on the injector or may still be located in the cylinder head. Either way, ensure that all 4 injector tip insulators are removed and discarded.

11. Remove and discard the fuel injector tip insulators.




12. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
13. Remove the fuel injector wiring harness clips from the fuel rail.
14. Remove the fuel injector wiring harness from the fuel rail.
15. Remove the fuel injectors, if necessary.

Installation Procedure

Important: Install only NEW lower O-rings if the fuel rail and injectors were removed and re-installed. If the fuel rail was replaced, then install NEW upper and lower O-rings.




1. Install the fuel injectors, if necessary.
2. Install the fuel injector wiring harness clips to the fuel rail.
3. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.




4. Lubricate the NEW fuel injector tip insulators with clean engine oil.
5. Install the NEW fuel injector tip insulators to the cylinder head.




6. Lubricate the fuel injector O-rings with clean engine oil.
7. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
8. Carefully push down on the fuel rail in order to insert the injectors into the cylinder head ports.

Notice: Refer to Fastener Notice.

9. Install the fuel rail bolts.

Tighten the bolts to 10 N.m (89 lb in).




10. Connect the engine harness electrical connector (2) to the fuel injector wiring harness electrical connector (1).
11. Install the fuel injector wiring harness electrical connector (1) clip to the intake manifold tab.




12. Install the 2 engine harness clips to the fuel rail tabs.
13. Connect the ETC electrical connector.




14. Connect the fuel feed line (1) quick connect fitting to the fuel rail.
15. Install the air cleaner outlet duct.
16. Connect the negative battery cable.
17. Inspect for fuel leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.