Fuel Rail: Service and Repair

Fuel Rail Removal and Installation:

Fuel Rail Assembly:

REMOVE OR DISCONNECT
1. Bleed fuel pressure from the fuel system.
2. Clean the fuel rail assembly and connections.
3. The fuel feed and fuel return pipes from the fuel rail tubes by choosing the correct tool from separator set J 37088-A for the size of the fitting. Insert the tool into the female end of the connector, push inward and pull the connector apart.
4. The Fuel injector coil wires.
5. The vacuum line from the vacuum source to the fuel pressure regulator.
6. The Manifold Absolute Pressure (MAP) sensor electrical connector.
7. The vacuum line to the vacuum switch from the fuel pipe bundle.
8. The vacuum source from the intake manifold.
9. The fuel injector electrical connectors.
10. The fuel injector harness fasteners (4).
11. The fuel rail hold-down bolts (4).
12. The fuel rail with equal force on both sides of the fuel rail.
13. The front fuel injector retaining clips on each side of the fuel rail.
14. The front fuel injector on each side of the fuel rail. The fuel rail will now clear the intake manifold.

CAUTION: 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.

WARNING: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector 0-rings in the proper position. If the upper and lower 0-rings are different colors (black and brown), be sure to install the black 0-ring in the upper position and the brown 0-ring in the lower position on the fuel injector The 0-rings are the same size but are made of different materials.

INSTALL OR CONNECT
1. The 0-rings must be replaced on all components that are replaced.
2. Lightly oil the fuel injector 0-rings with clean motor oil.
3. Place the fuel rail assembly (without the front fuel injectors on each side of the fuel rail) on the intake manifold.
4. The front fuel injector on each side of the fuel rail.
5. The fuel injector retaining clips on the front fuel injector on each side of the fuel rail.
6. Seat the fuel injectors by hand. Torque the fuel rail hold-down bolts to 10 Nm (7 ft lb).
7. The fuel injector harness fasteners.
8. The fuel injector electrical connectors.
9. The vacuum source to the intake manifold.
10. The vacuum line to the vacuum switch from the fuel pipe bundle.
11. The vacuum line from the vacuum source to the fuel pressure regulator.
12. The fuel feed and fuel return pipes by pushing the pipes onto the fuel rail tubes.
13. The MAP sensor electrical connector.
14. The fuel injector coil wires.

CAUTION:

^ Care must be taken not to damage/dirty the fuel injector electrical connectors, the fuel injector tips, the 0-rings, and the inlet and the outlet of the fuel rail.
^ Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components.
^ The fuel rail assembly must not be immersed in solvent in order to prevent damage to the fuel rail assembly.