Mazda RX-8 2004-06

Fuel Rail (Supply Manifold) & Injectors


Removal & Installation

Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion.

  1. Before servicing the vehicle, refer to the Precautions Section.
  3. Relieve the fuel system pressure.
  5. Remove or disconnect the following:

    Negative battery cable
    Upper and lower extension manifolds
    Variable Dynamic Effect (VDI) actuator and position out of the way
    Fuel injector wiring harness
    Fuel lines at the fuel rail
    Fuel distributor from intake manifold and housing sides
    Fuel rail with the injectors attached
    Fuel injectors, grommets and O-rings from the fuel rail
    O-rings from the fuel injectors

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and injector assembly-RX-8



To install:

  1. Install or connect the following:

    New O-rings and grommets lubricated with engine oil on the fuel injectors.
    Insulators and injectors on the intake manifold
    Grommets and the fuel rail onto the injectors. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
    Fuel lines to the fuel rail
    Fuel distributors
    Fuel injector wiring harness
    VDI actuator
    Negative battery cable

  3. Turn the ignition switch ON to pressurize the fuel system.
  5. Check for leaks and correct as necessary, before starting the engine.
  7. On models with dynamic suspension, perform the steering angle sensor initialization procedure.