Fuel Rail: Service and Repair

Resonator:

Fuel Rail Assembly:

REMOVAL PROCEDURE
1. Perform the Fuel Pressure Relief Procedure.
2. Remove the negative battery cable.
3. Loosen the air cleaner outlet duct clamp.
4. Remove the air cleaner outlet duct from air cleaner resonator.
5. Loosen the air cleaner resonator clamp at the throttle body.
6. Remove the bolts (1) attaching the resonator.
7. Remove the air cleaner resonator (2) from the throttle body (3).
8. Remove the crankcase vent hose to bottom of resonator, then remove the resonator.
9. Remove the fuel pipe clamp bolt.
10. Remove the vacuum hose at pressure regulator.
11. Remove the fuel rail attaching bolts.
12. Remove the fuel rail assembly (1) from cylinder head.
13. Remove the injector electrical connectors. Push in wire connector clip, while pulling connector away from fuel injector.
14. Remove the fuel inlet pipe at fuel rail. (Use a backup wrench on the fuel rail inlet fitting to prevent it from turning).
15. Loosen fuel return pipe retaining bracket attaching screw (7). (Rotate retaining bracket (8) to allow fuel pipe to be removed).
16. Remove the fuel return pipe from pressure regulator (11).
17. Remove the fuel rail assembly.
18. Remove the inlet and return pipe to fuel feed and return line connections.
19. Remove the inlet and return pipe assemblies. Discard O-rings (9).


INSTALLATION PROCEDURE

NOTE:
- Apply a few drops of clean engine oil to the male end of the fuel pipes before installing.
- Whenever there is not enough thread-locking material on the threads of the fuel outlet pipe bracket screw, apply Loctite� 262 to insure proper locking.


1. Whenever the fuel rail is disconnected from fuel pipes, reconnect fuel pipes to rail at this time.
2. Install the return pipe into regulator (11).
- (Align bracket to retain return pipe).

Tighten
Return pipe bracket screw (7) to 6.0 Nm (53 lb. in.).
- Use a backup wrench on the fitting to prevent it from turning.

Fuel inlet pipe nut to 30 Nm (22 lb. ft.).

Important: Rotate fuel injector(3) as required to avoid stretching the wire harness.

3. Position fuel rail (1) over cylinder head and connect fuel injector electrical connectors.
4. Install the fuel rail assembly into cylinder head.
5. Install the fuel rail assembly attaching bolts.

Tighten
Bolts to 26 Nm (19 lb. ft.).

6. Install the vacuum hose to fuel pressure regulator (11).
7. If front (engine) fuel pipes are being replaced, install new fuel pipe O-rings (9), coated with clean engine oil.
- Use a backup wrench to prevent female fitting from turning.
8. Install the inlet and return pipe connections.

Tighten
Fittings to 27 Nm (20 lb. ft.).

9. Install the fuel pipe clamp bolt.

Tighten
Bolt to 12 Nm (106 lb. in.).

Important: Apply a few drops of clean engine oil to the vent hose and the air cleaner resonator before installing.

10. Install the crankcase vent hose to bottom of the air cleaner resonator.
11. Install the air cleaner resonator (2) to throttle body (3).

Tighten
Clamp to throttle body 4-5 Nm (35-44 lb. in.).

12. Install the air cleaner resonator attaching bolts (1).

Tighten
Bolts to 10 Nm (89 lb. in.).

13. Air cleaner outlet duct to air cleaner resonator.

Tighten
Clamp to 4-5 Nm (35-44 lb. in.).

14. Install the negative battery cable.
15. Inspect for fuel leaks through the following steps:
1. Turn the ignition switch to the ON position for two seconds.
2. Turn the ignition switch to the OFF position for ten seconds.
3. Turn the ignition switch to the ON position.
4. Check for fuel leaks.