Fuel Rail: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
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.




1. Remove the fuel injector sight shield.




2. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure. Service and Repair
3. Clean the fuel rail assembly and the connections.
4. Remove the quick connect fitting for the fuel feed (1) and fuel return pipe (5) from the fuel rail.




5. Disconnect the fuel pressure regulator vacuum hose (1).




6. Remove the engine electrical harness bolts on the camshaft covers.
7. Disconnect the electrical connectors (1) from the fuel injectors (3).




8. Pull up the lock release of the fuel injector connector.




9. Depress the lock tab (1) and lift the connector from the injector.




10. Release the 4 snap-lock tabs on the fuel rail assembly by pushing toward the camshaft covers and lifting.

IMPORTANT: The fuel rail will pivot allowing each side of the rail to release separately.

11. Remove the fuel rail (1).

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 injector. 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) onto the intake manifold. A snap will be heard when the injectors are properly seated.




4. Connect the electrical connectors (1) to the fuel injectors (3).




5. Push the slide lock into the looked on all injector connectors.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the engine electrical harness bolts on the camshaft covers.

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




7. Install the fuel pressure regulator vacuum hose.




8. Install the fuel return pipe (5) and fuel feed pipe (1) to the fuel rail.
9. Install the to the fuel rail tube.
10. Connect the negative battery cable.




11. Perform the following procedure to inspect for fuel leaks:
11.1. Turn the ignition switch ON for 2 seconds.
11.2. Turn the ignition switch OFF for 10 seconds.
11.3. Turn the ignition switch ON.
11.4. Check for leaks.
12. Install the fuel injector sight shield.