Fuel Injector and Fuel Rail Removal and Installation

Tools

• 10 mm socket, ratchet, and 6" extension
• Flat-tip screwdriver
• Thin-head 24 mm or 15/16" open-end wrench
• 19 mm open-end wrench
• Small flat-tip screwdriver or probe
• Catch rags

Fuel Rail Removal

1. Disconnect the battery negative lead.

Note: Place catch rags under the fuel pressure damper and fuel pressure regulator before disconnecting fuel supply and return lines, to catch escaping fuel.

2. On 1985.5 and newer cars, use the thin-head 24 mm or 15/16" open-end wrench to hold the fuel pressure damper retaining nut and disconnect the fuel supply line using the 19 mm wrench. On 1985 and older cars, disconnect the fuel supply line at the connection on top of the intake manifold.

Note: The fuel supply line connects to the fuel damper; the fuel return line connects to the fuel pressure regulator. On 1985 and older cars, the damper and regulator are located next to each other near the back of the fuel rail. On 1985.5 and newer cars, the damper is at the front of the fuel rail and the regulator is near the back.

3. Using a flat-tip screwdriver, loosen the retaining clamp on the fuel return line and disconnect it from the fuel pressure regulator.
4. Disconnect the vacuum lines from the fuel damper and fuel pressure regulator.
5. Remove the plastic cover from the fuel rail.
6. Using a small flat-tip screwdriver or probe, disengage the wire clips on the fuel injector electrical connector plugs and disconnect the plugs. Move the wiring harness clear.
7. Using the 10 mm socket, remove the four fuel rail retaining bolts.

Note: The two bolts closest to the intake manifold are difficult to see — they are located below the fuel damper and fuel pressure regulator.

8. Disconnect the spark plug wire retaining clips from the fuel rail.

Note: The routing of spark plug wires to cylinders 3 and 4 may require the plug wires to be disconnected and removed before the fuel rail can be removed.

9. Grasp the fuel rail and pull firmly upward away from the intake manifold. The fuel injectors will come out with the fuel rail.

Fuel Injector Removal and Installation

1. The fuel injectors are held into the fuel rail by retaining clips near the top of the injector body. Note the orientation of the clips before removing them.
2. Check the condition of the injector O-ring seals and injector caps (hats) before installing injectors.
3. Ensure the injector retaining clips are properly installed before installing the fuel rail.

Fuel Rail Installation

Note: Route spark plug wires as the fuel rail is installed.

1. Ensure fuel injectors are correctly attached to the fuel rail with retaining clips.
2. Install the fuel rail, ensuring the fuel injectors seat into the holes in the intake manifold.
3. Torque the four fuel rail retaining bolts (M6) to 8 Nm (6 ft-lb).
4. Route the fuel injector wiring harness along the top of the fuel rail and connect the harness plugs to the injectors.
5. Install the plastic fuel rail cover.
6. Connect the fuel supply and return lines.
7. Connect the fuel damper and fuel pressure regulator vacuum lines.
8. Reconnect the battery.
9. Turn the ignition on to pressurize the fuel system and check for leaks.