Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE





TOOLS REQUIRED
^ J 34730 Fuel Pressure Gauge
^ J 37088-A Fuel Line Quick-Connect Tools

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.
^ Always maintain cleanliness when servicing fuel system components.

1. Remove the injector sight shield.




2. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
3. Clean the fuel rail assembly and connections.
4. Remove the fuel feed (1) pipe quick connect fitting by squeezing tabs and pulling the lines apart.
5. Remove the return (5) pipe quick connect fitting from the fuel rail.




6. Remove the vacuum hose (1) from the fuel pressure regulator (2).




7. Remove the PCV valve (1) hose.
8. Remove the throttle body vacuum port hose (2).
9. Remove the snap bracket on the throttle body coolant tube.




10. Remove the engine electrical harness bolt(s) on the camshaft cover(s).
11. Remove the fuel injector electrical connectors (1) from the fuel injectors (3).




12. Release the four snap locking tabs on the fuel rail assembly by pushing toward the camshaft covers and lifting.
13. Remove the fuel rail (1) with equal force on both sides of the fuel rail.

IMPORTANT: Store the fuel rail assembly in a clean, secure location away from heat sources.

INSTALLATION PROCEDURE





CAUTION: 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 enactor. The O-rings are the same size but are made of different materials.

NOTE:
^ 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 with clean motor oil.
3. Install the fuel rail assembly (1) on to the intake manifold.
4. A snap will be heard when the injectors are properly seated.




5. Install the fuel injector electrical connectors (1) on to the fuel injectors (3).
6. Install the engine electrical harness bolt(s) on the camshaft cover(s).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten
Tighten the bolts to 9 N.m (80 lb in).




7. Install the snap bracket on the throttle body coolant tube.
8. Install the throttle body vacuum port hose (2).
9. Install the PCV valve (1) hose.
10. Install the vacuum hose to the pressure regulator.




11. Install the fuel return pipe (5) to the fuel rail tube.
12. Install the fuel feed (1) pipe to the fuel rail tube.
13. Install the negative battery cable.




14. Inspect for fuel leaks.
14.1. Turn the ignition switch to the On position for 2 seconds.
14.2. Turn the ignition switch Off for 10 seconds.
14.3. Turn the ignition switch to the On position.
14.4. Check for leaks.
15. Install the injector sight shield.