Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027)Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
3. Disconnect the fuel feed line quick connect fitting (3) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.




4. Disconnect the engine wiring harness electrical connector (3) from the fuel injector wiring harness electrical connector (4).




5. Disconnect the fuel injector wiring harness electrical (1) from the manifold absolute pressure (MAP) sensor.




6. Remove the engine wiring harness clips (1) from the fuel rail tabs (2).




7. Remove the fuel rail bolts.

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

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





Note: 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.

10. Remove and discard the fuel injector tip insulators.




11. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
12. Remove the fuel injector wiring harness clips from the fuel rail.
13. Remove the fuel injector wiring harness from the fuel rail.
14. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement Service and Repair.

Installation Procedure

Note: 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. Refer to Fuel Injector Replacement Service and Repair.
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.
Caution: Refer to Fastener Caution Fastener Caution.

9. Install the fuel rail bolts and tighten to 10 Nm (89 lb in).




10. Install the engine wiring harness clips (1) to the fuel rail tabs (2).




11. Connect the fuel injector wiring harness electrical (1) to the MAP sensor.




12. Connect the engine wiring harness electrical connector (3) to the fuel injector wiring harness electrical connector (4).




13. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.
14. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.
16. 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.