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Pelican Technical Article:

Fuel Rail Removal

Steve Vernon

Time:

1 hour1 hr

Tab:

$0

Talent:

**

Tools:

14mm flared nut wrench, T30 Torx

Applicable Models:

Porsche 955 Cayenne GTS (2008-10)
Porsche 955 Cayenne S (2008-10)
Porsche 955 Cayenne Turbo (2008-10)
Porsche 955 Cayenne Turbo S (2009-10)
Porsche 970 Panamera 4S (2010-14)
Porsche 970 Panamera GTS (2013-14)
Porsche 970 Panamera S (2010-14)
Porsche 970 Panamera Turbo (2010-14)
Porsche 970 Panamera Turbo Executive (2014)
Porsche 970 Panamera Turbo S (2012-14)
Porsche 970 Panamera Turbo S Executive (2014)

Parts Required:

fuel rail

Hot Tip:

Cover the injectors when the rail is out

Performance Gain:

Access to other components

Complementary Modification:

Replace injectors

The fuel rail in the direct injection motors in the Porsche Cayenne is a stainless steel piece that usually lasts the life of the vehicle and does not often fail or need to be replaced, but it does need to be moved to give access to other components or perform other work. When removing the rail carefully inspect it for any signs of it failing. Since it carries over 1,700 psi of pressure if it starts failing it is pretty obvious.

The rail gets its fuel and pressure from the high pressure pump on the left cylinder bank. The left side cam drives the pump. Once the engine is off it dissipates the pressure quickly. That being said even when the engine is cold there will be some residual fuel in the rail. Be prepared to catch it and dispose of it correctly.

As always when working around fuel take all necessary precautions: wear gloves and eye protection, work in a well ventilated area and do not work around any open flame or hot lights. Let the motor cool down before beginning work

The fuel rail is located below the intake manifold; please see our article on intake manifold removal for further assistance in removing it.
Figure 1

The fuel rail is located below the intake manifold; please see our article on intake manifold removal for further assistance in removing it.

With the intake manifold removed you can see the stainless steel fuel rail and the lines that run to each of the injectors (red arrow).
Figure 2

With the intake manifold removed you can see the stainless steel fuel rail and the lines that run to each of the injectors (red arrow). The knock sensors and starter motor are located below the rail.

On the rear of the left bank is the high pressure pump (red arrow) that provides the fuel and pressure for the rail (yellow arrow).
Figure 3

On the rear of the left bank is the high pressure pump (red arrow) that provides the fuel and pressure for the rail (yellow arrow).

Begin by disconnecting the wiring for the high pressure fuel sensor located in the middle of the rail (red arrow).
Figure 4

Begin by disconnecting the wiring for the high pressure fuel sensor located in the middle of the rail (red arrow).

You are going to be disconnecting the fuel input line as well as the lines to the injectors.
Figure 5

You are going to be disconnecting the fuel input line as well as the lines to the injectors. Make sure you use a proper 14mm flared nut wrench (red arrow). While these fittings are not tight you do not want to round any of them. If you round off a fitting on the rail you will have to replace the entire rail, as it is one solid welded piece. Loosen all the fittings on the injectors. Be ready to catch the small amount of fuel that will spill out and dispose of it according to the regulations in your area.

Use a 14mm flared nut wrench and remove the input line from the pump (red arrow).
Figure 6

Use a 14mm flared nut wrench and remove the input line from the pump (red arrow). There will be some fuel left in the line that will spill out when you loosen this fitting.

Use a T30 Torx and remove the four mounting bolts.
Figure 7

Use a T30 Torx and remove the four mounting bolts. Three of them are the same size (red arrows) but the left front is long (yellow arrow). Make sure to keep that in mind when reinstalling.

With the mounting bolts removed you can lift the rail out from the motor.
Figure 8

With the mounting bolts removed you can lift the rail out from the motor. You will need to move it around the rear area but it comes out without removing any other components.

Immediately cover the injector openings even if you are going to be reinstalling the rail in a short amount of time.
Figure 9

Immediately cover the injector openings even if you are going to be reinstalling the rail in a short amount of time. You do not want any dirt or debris getting into the top of the injectors. The injector to rail connections does not have any gasket or O-ring so it is important to keep everything very clean. I like to use the fingers for rubber gloves and then small zip ties to protect the injectors (red arrow). If you are leaving the rail off the motor you should cover the ends of the rail as well. Installation is the reverse of removal.



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