Fuel Rail & Injector Removal Problem

[Rick Thomson]

I thought removing the fuel rail and injectors would be a simple task, but it has not been so far. This is a low-mileage car, so the parts in question are all original.

My first attempt was to remove the rail and injectors as an assembly after removing the fuel supply and return lines, the vacuum lines, and the four bolts retaining the rail brackets. When applying what I considered a reasonable force to the assembly, the injectors did not budge. They can be wiggled in all directions, but will not move vertically. I applied rust penetrant to the injectors and waited 24 hours before trying again, but nothing changed.

Next, I tried to separate the fuel rail from the injectors. I disconnected the harness connectors and removed the clips. The result was the same. The fuel rail seems to be exerting the same grip on the injectors as the head.

Has anyone else run into a similar problem? If so, how did you resolve it? I would prefer not to resort to extreme measures that would likely require purchasing a new injector set.

[Tom]

I thought removing the fuel rail and injectors would be a simple task, but it has not been so far. This is a low-mileage car, so the parts in question are all original.

My first attempt was to remove the rail and injectors as an assembly after removing the fuel supply and return lines, the vacuum lines, and the four bolts retaining the rail brackets. When applying what I considered a reasonable force to the assembly, the injectors did not budge. They can be wiggled in all directions, but will not move vertically. I applied rust penetrant to the injectors and waited 24 hours before trying again, but nothing changed.

Next, I tried to separate the fuel rail from the injectors. I disconnected the harness connectors and removed the clips. The result was the same. The fuel rail seems to be exerting the same grip on the injectors as the head.

Has anyone else run into a similar problem? If so, how did you resolve it? I would prefer not to resort to extreme measures that would likely require purchasing a new injector set.

If the 4 bolts are out and the hoses and connectors are all removed, you just need to pull harder. The o-rings can get pretty attached to their ports over time. Work on the front or back first, and try to pry with your hand around the rail and pressing the intake with your thumb. That helps prevent you and the rail from going flying when it comes free.

[spacecad3t]

I thought removing the fuel rail and injectors would be a simple task, but it has not been so far. This is a low-mileage car, so the parts in question are all original.

My first attempt was to remove the rail and injectors as an assembly after removing the fuel supply and return lines, the vacuum lines, and the four bolts retaining the rail brackets. When applying what I considered a reasonable force to the assembly, the injectors did not budge. They can be wiggled in all directions, but will not move vertically. I applied rust penetrant to the injectors and waited 24 hours before trying again, but nothing changed.

Next, I tried to separate the fuel rail from the injectors. I disconnected the harness connectors and removed the clips. The result was the same. The fuel rail seems to be exerting the same grip on the injectors as the head.

Has anyone else run into a similar problem? If so, how did you resolve it? I would prefer not to resort to extreme measures that would likely require purchasing a new injector set.

Gentle persuasion, aka pry bar. Like Tom said, if the 4 bolts are removed, take a cheater bar and gently pry up. I usually start in the middle and then work the ends. The seals are likely just embedded in the aluminum now and need broken. Don't panic if the plastic caps get left behind, just take a pick and dig them out.

[Rick Thomson]

spacecad3t: The judicious use of a pry bar did the trick. A lot of tension and hand-wiggling were required to separate them from the fuel rail. I packed them up and sent them to SouthBay Fuel Injectors for servicing.

Thank you for your advice.