Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
IMPORTANT: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. The fittings should be capped, and the holes should be plugged during servicing.
1. Remove the fuel injection sight shield
2. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
3. Clean the fuel rail assembly and connections.
4. Remove the fuel feed, (2) and return pipes (1) from the fuel rail tubes.
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 with the purge valve attached.
8. Remove the bypass valve actuator.
9. Depress the lock tab and disconnect the electrical connectors from the fuel injectors.
10. Remove the fuel injector electrical harness clips holding harness to front of fuel rail.
11. Remove the fuel rail hold-down nuts.
12. Remove the fuel rail with equal force on both sides of the fuel rail.
INSTALLATION PROCEDURE
CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the 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 fuel injector. The O-rings are the same size but are made of different materials.
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 (89 lb in).
5. Install the bypass valve actuator.
6. Install the rear generator mounting bracket with the evaporative emission (EVAP) canister purge valve attached.
7. Connect the fuel injector electrical harness clips to the front of fuel rail.
8. Connect the fuel injector electrical connectors to the fuel injectors.
9. Install the ignition coil wires to the retainer clips on top of super charger.
10. Connect the vacuum line to the fuel pressure regulator.
11. Connect the fuel feed, (2) and return pipes (1) to the fuel rail tubes.
12. Tighten the fuel fill cap.
13. Connect the negative battery cable.
14. Inspect for leaks using the following procedure:
14.1. Turn ON the ignition, for 2 seconds.
14.2. Turn OFF the ignition, for 10 seconds.
14.3. Turn ON the ignition.
14.4. Inspect for fuel leaks.
15. Install the fuel injection sight shield.