Fuel Rail: Service and Repair

FUEL RAIL REMOVAL/INSTALLATION - 3.0L

Removal

WARNING:Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING:Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.
1. Release the fuel system pressure. See Service and Repair

2. Disconnect the battery ground cable. See Battery Disconnect.

3. Remove the upper intake manifold. See - Upper Intake Manifold Removal/Installation.

4. Disconnect the fuel supply tube quick connect coupling at the fuel rail. See - Quick Release Coupling - Double Locking.

5. Release the 4 wire harness pin-type retainers from the fuel rail.

6. Release the engine wire harness electrical connector pin-type retainer from the fuel rail.

7. Disconnect the 6 fuel injector electrical connectors.

8. Remove the 4 fuel rail bolts.

9. Remove the fuel rail and injectors as an assembly.

10. Remove the 6 clips and the fuel injectors.

- Remove and discard the 12 fuel injector O-ring seals.

Installation

1. Install the 6 fuel injectors and clips on the fuel rail.

CAUTION:Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE:The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
NOTE:Install new fuel injector O-ring seals and lubricate them with clean engine oil.
2. Position the fuel rail and install the bolts.

- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.

3. Connect the engine wire harness electrical connector pin-type retainers to the fuel rail.

4. Connect the 4 wire harness pin-type retainers to the fuel rail.

5. Connect the fuel supply tube quick connect coupling at the fuel rail. See - Quick Release Coupling - Double Locking.

6. Connect the 6 fuel injector electrical connectors.

7. Install the upper intake manifold. See - Upper Intake Manifold Removal/Installation.

8. Connect the battery ground cable. See Battery Disconnect.