Fuel Rail: Service and Repair

REMOVAL

1. Disconnect the negative battery cable.

2. Remove engine air cleaner intake tube and duct from air cleaner to throttle body.

3. Remove the fuel filler cap to relieve fuel tank pressure.

4. Release pressure from fuel system at fuel pressure relief valve.

5. Remove upper intake manifold.

Fuel Injection Supply Manifold:

6. Disconnect fuel supply and return line retaining clips.

7. Disconnect the fuel chassis inlet and outlet fuel hoses from the fuel supply manifold.

Fuel Injection Supply Manifold:

8. Remove four (two per group) fuel supply manifold retaining bolts.

NOTE: Fuel injectors will stay in fuel injection supply manifold when removed.






9. Remove manifold.

INSTALLATION

1. Make sure injector caps are clean and free of contamination.






2. Install fuel injectors into fuel injection supply manifold, then seat fuel injectors into pockets in lower intake manifold. Make sure the fuel injectors are properly seated.

3. Secure the fuel injection supply manifold using four retaining bolts. Tighten to 8-12 Nm (71-105 lb in).

4. Connect the fuel inlet and outlet lines at the fuel injection supply manifold connections as follows:

a. Check for missing or damaged garter spring, remove damaged spring with small hooked wire, and install new spring.

b. Clean fittings with solvent. Check for missing or damaged O-rings. Replace missing O-rings. If either O-ring is damaged, replace both.

c. Assemble fitting by pushing with a slight twisting motion.

d. To check coupling engagement, pull on fitting and visually check to be sure garter spring is over flared end of female fitting.

5. Connect fuel retaining clips.

6. Install upper intake manifold.

7. Install engine air cleaner intake tube and duct to air cleaner to throttle body.

8. Connect the negative battery cable.