Fuel Rail: Service and Repair

FUEL RAIL

Part 1:

Part 2:

Exploded Views

Removal and Installation

Disconnect Tool, Spring Lock Coupling:

Special Tool(s)

1. 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 can be ignited. Failure to follow these instructions may result in personal injury.
- Fuel in the 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 must be relieved. Failure to follow these instructions can result in personal injury.

NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials shall be removed prior to installation.

Disconnect the battery ground cable.

2. Remove the air cleaner assembly.
3. Release the fuel system pressure.
4. Disconnect the throttle position (TP) sensor electrical connector.
5. Disconnect the idle air control (IAC) sensor electrical connector.
6. Disconnect the fuel pulse damper electrical connector and vacuum hose.
7. Disconnect the 8 fuel injector electrical connectors.
8. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
9. Disconnect the brake booster hose from the intake manifold.
10. Disconnect the engine emissions vacuum hose from the intake manifold.
11. Disconnect the evaporative emission (EVAP) canister purge valve vacuum hose from the intake manifold.
12. Remove the upper intake manifold-to-lower intake manifold bracket nuts.
- To install, tighten to 10 Nm (89 lb-in).

13. Remove the upper intake manifold-to-lower intake manifold bracket.







14. Remove the fuel tube safety clip.







15. Install the special tool.







16. Close and push the special tool into the open side of the cage.







17. Disconnect the fuel tube.
- To install, align the fuel tube fittings and press together until an audible click is heard.
- Pull on the fittings to make sure they are fully engaged, and then install the safety clip.

18. Disconnect the EGR system tube nuts and remove the tube.
- To install, tighten to 40 Nm (30 lb-ft).

19. Disconnect the throttle return spring from the throttle body.
20. Disconnect the accelerator cable and the speed control cable (if equipped) from the throttle body.
21. Remove the accelerator cable assembly bracket bolts and position the bracket and cables aside.
- To install, tighten to 10 Nm (89 lb-in).

22. Remove the fuel rail bolts and the fuel rail.
- To install, tighten to 10 Nm (89 lb-in).

23. To install, reverse the removal procedure.