Fuel Rail: Service and Repair

REMOVAL:

1. Disconnect the negative battery cable.
2. Disconnect the cold start injector fuel pipe.
3. Remove the throttle body. Refer to THROTTLE BODY for proper procedure.
4. Disconnect electrical connectors from injectors.
5. Remove the Fuel Pressure Regulator (FPR) form the fuel rail.
6. Remove the accelerator cable brackets.

Removing The RH Accelerator Cable Bracket:

7. Disconnect the two wire clips for the engine wire from the timing belt cover.

Removing The Wire Clamps From The No.2 Timing Belt Cover:

8. Disconnect the two wire clamps from the brackets on the intake manifold.

Disconnecting The Wire Clamps From The Intake Manifold:

9. Disconnect the fuel return hose from the pipe.

Disconnect The Fuel Line From The Fuel Return Pipe:

10. Using a wrench, remove the Fuel Pressure Pulsation Damper along with the two sealing gaskets.

Loosening The Fuel Pulsation Damper:

11. Remove the two Fuel Rail mounting bolts.

Loosening The Fuel Rail Mount Bolts:

12. Lift the Fuel Rail with the injectors from the cylinder head.

CAUTION: Be careful that the injectors do not drop from the Fuel Rail. Damage to the injector tip could result.

13. Remove the four insulators and two spacers from the cylinder head.
14. When the Fuel Rail is safely over a workbench, pull the injectors from the Fuel Rail.

INSTALLATION:

1. Install new grommet and O-ring on each removed injector.

Fuel Injector O-Ring:

2. Apply a light coat of gasoline to the O-ring to ease insertion into the Fuel Rail.
3. With a twisting motion, install each injector into the Fuel Rail until fully seated. Carefully check proper alignment to prevent fuel leaks.

Correct Installation Of Injectors To Fuel Rail:

4. Place four new insulators and two spacers in position on the cylinder head.

FI Insulator And FR Spacer Locations On The Cylinder Head:

5. Carefully install the Fuel Rail with injectors on the cylinder head.

Removing The Fuel Rail:

6. Start the two mounting bolts, but do not tighten. Rotate each injector to ensure that there is no binding of the sealing parts.

Checking For Correct Rotation Of The Fuel Injectors:

7. If the injectors do not rotate smoothly, recheck the O-rings for correct installation.
8. Position injector connector sockets facing up.
9. Torque the two mounting bolts to 9 ft.lbs. (13 N-m).
10. Install the Fuel Pressure Pulsation Damper using two new gaskets. Torque the damper to 9 ft.lbs. (13 N-m).

Fuel Pressure Pulsation Damper:

11. Connect the fuel return hose.
12. Connect injector electrical connectors.
13. Install the two wire clamps on the brackets on the intake manifold.
14. Install the engine wire with the two clips on the timing belt cover.
15. Install accelerator cable brackets.
16. Install fuel pressure regulator.
17. Connect cold start injector fuel delivery pipe with two new gaskets. Torque the union bolt to 13 ft.lbs. (18 N-m).
18. Install throttle body. Refer to THROTTLE BODY for proper procedure.
19. Reconnect negative battery cable.
20. Start engine and check for fuel leaks.