Fuel Rail: Service and Repair

WARNING: 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 ins tail 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.

CAUTIONS:
- 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.

- Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.

- Do not use the compressed to clean the fuel rail assembly as this may damage the fuel rail components.

- Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

REMOVE OR DISCONNECT
An eight digit identification number is stamped on the left hand fuel rail (fueling even cylinders 2,4,6), Refer to this number if servicing or part replacement is required).

1. Relieve fuel system pressure, refer to Fuel Pressure Release.
2. Upper intake manifold.




3. Engine fuel feed pipe at fuel rail.




4. Engine fuel return pipe at fuel rail.




5. Main injector harness electrical connector.




6. Coolant temperature sensor electrical connector.




7. Fuel rail retaining bolts.
8. Fuel rail assembly.
9. Injector O-ring seal from spray tip end of each injector. Discard seals. With the O-ring removed, the O-ring backup may slip off of the injector. Be sure to retain the O-ring backup for reuse.




10. Fuel injector electrical connectors at the fuel injectors.
11. Fuel injector electrical harness from the fuel rail.

INSTALL OR CONNECT
1. Fuel injector electrical harness from the fuel rail.
2. Fuel injector electrical connectors at the fuel injectors.
3. Ensure that O-ring backups are on injectors before installing new O-rings. Lubricate new injector O-ring seals with clean engine oil and install on spray tip end of each injector.
4. Fuel rail assembly in intake manifold. Tilt rail assembly to install injectors.
5. Fuel rail attaching bolts and tighten to 10 Nm (89 lb in).
6. Coolant temperature sensor electrical connector.
7. Main injector harness electrical connector.
8. Fuel feed pipe at the fuel rail and tighten the pipe nut to 17 Nm (13 lb ft).
9. Fuel return pipe at the pressure regulator and tighten the pipe nut to 17 Nm (13 lb ft).
10. Upper intake manifold.
11. Fuel filler cap.