Fuel Rail: Service and Repair
REMOVALFuel Injector Harness Connections:
1. Fuel system pressure must be released prior to service. Service and Repair
2. Disconnect negative battery cable and remove air cleaner assembly.
3. Disconnect fuel injector harness and detonation (knock) sensor electrical connectors from the main engine harness.
Electrical, Fuel, And Vacuum Connections:
4. Loosen and remove supply and return hoses from fuel rail assembly.
5. Disconnect the vacuum, vapor hose connection.
6. Disconnect the fuel pressure regulator vacuum hose at the regulator.
7. Disconnect the electrical connector from the charge temperature sensor (Turbo IV).
Fuel Rail Attaching Screws:
8. Remove the fuel tube clamp screw.
9. Remove the fuel rail mounting bolts.
10. Remove the fuel rail and injector assembly by pulling the rail so that the injectors come straight out of their ports.
11. Inspect injector O-rings upon removal and discard any that appear damaged or worn.
12. Cover fuel injector ports while injectors are removed.
13. Do not disassemble the fuel rail until it has been removed from the vehicle.
INSTALLATION
Fuel Rail And Injector Assembly:
1. Be certain injectors are seated into receiver cups and retainer rings are in place before attempting to install fuel rail assembly.
2. Install injector wiring harness into injectors and fasten into wiring clips. Make sure injector ports are clean and any plugs have been removed.
3. Lube injector O-rings with clean motor oil and install the injector/rail assembly into the injector ports. Install the 2 fuel rail mounting bolts and ground straps. (Make sure fuel rail seats evenly with all injectors seated in their ports.) Torque mounting bolts to 200 lb-in (22.5 Nm).
Fuel Injector Harness Connections:
4. Reconnect detonation (knock) sensor electrical connector.
5. Connect vacuum hose to fuel pressure regulator.
6. Close fuel tube clamp around fuel tubes and mount the clamp screw to the manifold.
7. Connect the fuel injector and charge temperature sensor electrical connectors to the main engine harness.
8. Connect fuel supply and return hoses to fuel tube assembly and torque hose clamps to 1 Nm (10 lbs.in.). Connect the fuel injector electrical connectors, and install air cleaner. Connect negative battery cable.
9. Pressurize fuel system and check for leaks. [1][2]Fuel System Leak Test