Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT (VIN 1)

REMOVAL PROCEDURE

IMPORTANT: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.




1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
2. Remove the fuel injection sight shield.
3. Clean the fuel rail assembly and connections.
4. Remove the fuel feed, (2) and return pipes (1) from the fuel rail tubes. Refer to Quick Connect Fitting(s) Service (Metal Collar).




5. Disconnect the vacuum line from the fuel pressure regulator.
6. Disconnect the ignition coil wires from the retainer clips on top of super charger.
7. Remove the rear generator mounting bracket if the purge valve attached.
8. Remove the bypass valve actuator.




9. Pull up the lock release (2) on the fuel injector harness connector (2).
10. Depress the lock tab (1) and lift the harness connector from the fuel injector.
11. Repeat steps 8 - 9 for all injectors.
12. Remove the fuel injector electrical harness clips holding harness to front of fuel rail.




13. Remove the fuel rail hold-down nuts.
14. Remove the fuel rail with equal force on both sides of the fuel rail.

INSTALLATION PROCEDURE

IMPORTANT: The O-rings must be replaced on all components that are serviced.




1. Lightly oil the fuel injector O-rings with clean motor oil.
2. Place the fuel rail assembly on the intake manifold.
3. Seat the fuel injectors by HAND.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the fuel rail hold-down nuts (4).

Tighten
Tighten the fuel rail hold-down nuts to 10 N.m (7 lb ft).

5. Install the bypass valve actuator.
6. Install the rear generator mounting bracket with the EVAP canister purge valve attached.
7. Connect the fuel injector electrical harness clips to the front of fuel rail.




8. Connect the fuel injector harness (1) connectors to the fuel injectors.
9. Push down the lock release lever (2) until it locks.
10. Install the ignition coil wires to the retainer clips on top of super charger.




11. Connect the vacuum line to the fuel pressure regulator.




12. Connect the fuel feed, (2) and return pipes (1) to the fuel rail tubes. Refer to Quick Connect Fitting(s) Service (Metal Collar).
13. Tighten the fuel fill cap.
14. Connect the negative battery cable.
15. Inspect for leaks using the following procedure:
15.1. Turn ON the ignition, for 2 seconds.
15.2. Turn OFF the ignition, for 10 seconds.
15.3. Turn ON the ignition.
15.4. Inspect for fuel leaks.
16. Install the fuel injection sight shield.