Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.

Warning

In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Note: If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.




1. Disconnect the fuel feed pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
2. Disconnect any remaining electrical connectors.
3. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement (Upper Intake Manifold Replacement).
4. Remove the fuel injector harness connector bracket bolt from the intake manifold.
5. Disconnect the camshaft position (CMP) sensor electrical connector.
6. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
7. Remove the fuel rail bolts.
8. Remove the fuel rail.
9. Remove the O-ring from the spray tip end of each injector.
10. Discard the O-rings if damaged.





Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

11. Remove the fuel injector retaining clip (1), if required.
12. Remove the fuel injector (3) from the fuel rail, if required.
13. Remove the fuel injector upper O-ring (2), if required.

Installation Procedure





Note: Ensure to use the correct part number when ordering the replacement fuel injectors.

1. The fuel injector (1) is stamped with a part number identification (2).




2. Lubricate the NEW injector O-rings (2) with clean engine oil, if required.
3. Install the fuel injector upper O-ring (2), if required.
4. Install the fuel injector (3) to the fuel rail, if required.
5. Install the fuel injector retaining clip (1), if required.





Caution:
* Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
* Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
* Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

6. Replace any damaged lower injector O-rings that were removed.
7. Lubricate the lower injector O-rings with clean engine oil.
8. Install the fuel rail assembly into the intake manifold. Tilt the fuel rail assembly slightly to install the injectors.

Caution: Refer to Fastener Caution (Fastener Caution).

9. Install the fuel rail bolts.

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

10. Connect the CMP sensor electrical connector.
11. Disconnect the ECT sensor electrical connector.
12. Position the fuel injector harness connector bracket to the intake manifold.
13. Install the fuel injector harness connector bracket bolt.

Tighten the bolt to 8 Nm (71 lb in).

14. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement (Upper Intake Manifold Replacement).
15. Connect any remaining electrical connectors.
16. Connect the fuel feed pipe to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LGD/LZE) (Battery Negative Cable Disconnection and Connection).
18. Inspect for fuel leaks with the following procedure:

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