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 assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
3. Disconnect the fuel feed line quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




4. Disconnect the evaporative emission (EVAP) purge tube from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




5. Disconnect the fuel injector harness electrical connector (2).
6. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.




7. Remove the fuel injector harness electrical connector clips (4 and 5) from the intake manifold.




8. Remove the fuel rail studs.

Note: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and 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.
11. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement (Service and Repair).

Installation Procedure

Note: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.




1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement (Service and Repair).
2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
3. Carefully push the fuel injectors into the cylinder head ports.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the fuel rail bolts.

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




5. Connect the fuel injector harness electrical connector (2).
6. Connect the MAP sensor electrical connector.




7. Install the fuel injector harness electrical connector clips (4 and 5) to the intake manifold.




8. Connect the EVAP purge tube to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




9. Connect the fuel feed line quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
10. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).
12. 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.