Fuel Rail: Service and Repair

Fuel Rail Assembly Replacement

Removal Procedure





Caution: Refer to Fuel Pressure Notice Fuel Pressure Notice in Cautions and Notices.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure Service and Repair.

Caution: Refer to Battery Disconnect Caution Battery Disconnect Caution in Cautions and Notices.

2. Disconnect the negative battery cable.
3. Remove the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement Service and Repair.
4. Disconnect the fuel feeding pipe from the fuel rail.




5. Remove the intake manifold. Refer to Intake Manifold Replacement Service and Repair in Engine Mechanical.




6. Disconnect the fuel injector wiring harness connector.
7. Remove the fuel rail assembly.




8. Remove the fuel injector retainer clip.
9. Remove the fuel injectors by pulling them down and out.

Installation Procedure





Important: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.


1. Lubricate the new fuel injector O-rings with engine oil.
2. Install the new O-rings on the fuel injectors.
3. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
4. Install the fuel injector retaining clips onto the fuel injector and the fuel rail ledge.




5. Ensure that the clips are parallel to the fuse injector harness connector.
6. Install the fuel rail assembly into the cylinder head.
7. Connect the fuel injector wiring harness connector.




8. Install the intake manifold. Refer to Intake Manifold Replacement Service and Repair in Engine Mechanical - 2.5L.
9. Connect the fuel feeding pipe to the fuel rail.





Notice: Refer to Fastener Notice Fastener Notice in Cautions and Notices.

10. Install the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement Service and Repair.

Tighten the fuel pressure regulator retaining bolts to 12 Nm (106 lb in).

11. Connect the negative battery cable.
12. Perform a leak check of the fuel rail and fuel injectors.