Fuel Rail: Service and Repair

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Partially drain the cooling system.
4. Remove the air cleaner outlet pipe.







5. Remove the power steering reservoir upper bracket.







6. Disconnect the fuel pressure regulator valve vacuum hose.
7. Disconnect the fuel tubes.

CAUTION: After disconnecting, plug the fuel tubes to prevent leakage.







8. Disconnect the eight ignition coil electrical connectors.







9. Disconnect the eight fuel injector electrical connectors.







10. Remove the nut and disconnect the brake booster vacuum tube and bracket.







11. Remove the crankcase ventilation tube.







12. Disconnect and remove the Positive Crankcase Ventilation (PCV) hose.

NOTE: 4.6L shown, 5.4L similar.







13. Remove the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube.
^ Disconnect the exhaust manifold to EGR valve tube upper fitting.
^ Disconnect the differential pressure feedback EGR system electrical connector.
^ Disconnect the exhaust manifold to EGR valve tube lower fitting.







14. Disconnect the EGR valve vacuum hose and the evaporative emission canister purge valve hose and position them aside.







15. Remove the bolts and lift the fuel injection supply manifold and injectors upward, out of the intake manifold.







16. Remove the fuel injectors from the fuel injection supply manifold.







17. Inspect the two O-ring seals from each fuel injector. New O-ring seals will be installed as needed.

INSTALLATION







1. Install new O-ring seals, as required.

NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation.

2. Install the fuel injectors into the fuel injection supply manifold.







3. Position the fuel injection supply manifold and install the four bolts.







4. Connect the evaporative emission canister purge valve hose and the EGR valve vacuum hose.







5. Install the exhaust manifold to EGR valve tube.







6. Connect the differential pressure feedback EGR system electrical connector.







7. Install the positive crankcase ventilation (PCV) hose.

NOTE: 4.6L shown, 5.4L similar.







8. Install the crankcase ventilation tube.







9. Connect the brake booster vacuum tube and bracket and install the nut.







10. Connect the eight fuel injector electrical connectors.







11. Connect the eight ignition coil electrical connectors.
12. Connect the fuel tubes.







13. Connect the fuel pressure regulator valve vacuum hose.







14. Install the power steering reservoir upper bracket.
15. Install the air cleaner outlet pipe.
16. Fill the cooling system.
17. Connect the battery ground cable.