Fuel Rail: Service and Repair

REMOVE OR DISCONNECT
1. Bleed fuel pressure from the fuel system. Refer to Fuel Pressure Release.
2. Clean fuel rail assembly and connections.
3. Fuel feed and return pipes from the fuel rail tubes by squeezing tabs and pulling the lines off.
4. Vacuum line from the pressure regulator.
5. Vacuum line to throttle body.
6. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
7. Remove the generator and rear generator mounting bracket.
8. Remove injector electrical connectors.
9. Remove the injector electrical harness clips holding harness to front of fuel rail.
10. Fuel rail hold down bolts or nuts.
11. Fuel rail with equal force on both sides of the rail.

CAUTION:
- When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminates from entering the fuel passages. It is recommended that fittings be capped, and holes plugged during service.
- Care must be taken not to damage or dirty injector tips, the O-ring, and the inlet and the outlet of the fuel rail.
- Compressed air must not be used to internally flush, clean, dry the fuel rail assembly.
- Fuel rail assembly must not be immersed in solvent.

WARNING: To reduce the risk of fire and personal injury that may result from a fuel leak, always install injector O-rings in proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the injector. The O-rings are the same size but are made of different materials.

INSTALL OR CONNECT
1. O-rings must be replaced on all components that are replaced.
2. Lightly oil injector O-rings with clean motor oil.
3. Place rail on manifold assembly and seat injectors by hand.

Tighten
Bolts to 10 Nm (7 lb. ft.).

4. Install the generator and rear generator mounting bracket.
5. Install the injector electrical harness clips holding harness to front of the fuel rail.
6. Install the injector electrical connectors.
7. Install the ignition coil wires to coil and retainer clips on top of super charger.
8. Vacuum line to pressure regulator.
9. Vacuum line to throttle body.
10. Fuel feed and return pipes by pushing pipes onto the fuel rail tubes.