Fuel Rail: Service and Repair

Fuel Rail Assembly Replacement

Removal Procedure

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: When servicing the fuel rail assembly. precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped. and the holes be plugged during servicing.

Important: Always maintain cleanliness when servicing fuel system components.

1. Relive the fuel pressure from the fuel system. Refer to Fuel Pressure Release Procedure

2. Clean the fuel rail assembly and connections.




3. Disconnect the fuel feed, (1) and return pipes (2) from the fuel rail tubes. Refer to Fuel Line Coupler Service (Metal Collar).




4. Disconnect the vacuum line from the fuel pressure regulator.




5. Remove the ignition coil wires.




6. Disconnect the (6) injector electrical connectors.




7. Remove the fuel rail hold-down bolts.
8. Remove the fuel rail with equal force on both sides of the fuel rail.

Installation Procedure

WARNING: In order to reduce the risk of fire and personal injury that may result from a fuel leak always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.


Notice:
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
^ Do not use the compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
^ Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

1. The O-rings must be replaced on all components that are replaced.




2. Lightly oil the fuel injector O-rings (2), (3), with clean motor oil.




3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

Notice: Refer to Fastener Notice in Cautions and Notices.

5. Reinstall the fuel rail hold down bolts.
- Torque the fuel rail hold-down bolts to 10 N.m (88 lb in).
6. Connect the (6) fuel injector electrical connectors.




7. Connect the fuel feed (1) and return (2) pipes to the fuel rail tubes. Refer to Quick Connect Fitting(s) Service (Metal Collar).




8. Connect the vacuum line to the fuel pressure regulator.




9. Connect the ignition coil wires.
10. Inspect for leaks.
10.1. Turn the ignition switch ON for 2 seconds.
10.2. Turn the ignition switch OFF for 10 seconds.
10.3. Turn the ignition switch ON.
10.4. Check for fuel leaks.




11. Reinstall the injector sight shield. Refer to Engine Cover Replacement Service and Repair.