Fuel Rail: Service and Repair
REMOVALFuel Hoses And Connectors:
1. Fuel system pressure must be released prior to service. Service and Repair
2. Disconnect negative battery cable and remove air cleaner assembly.
3. Disconnect fuel injector harness electrical connector and detonation (knock) sensor electrical connector.
Fuel Rail And Fuel Pressure Regulator:
4. Loosen and remove supply and return hoses from fuel rail assembly.
5. Using 2 wrenches, one on the fuel pressure regulator, and the other on the fuel return tube nut, loosen the fuel return tube nut. Open the fuel tube fastener and remove the fuel tube.
6. Remove the 2 fuel pressure regulator attaching nuts and disconnect the fuel pressure regulator vacuum hose at the regulator. Remove the fuel pressure regulator from the fuel rail.
7. Remove the PCV vacuum harness and vacuum vapor harness from the intake manifold.
Fuel Rail:
8. Remove the fuel rail to intake manifold attaching screws, and pull the fuel rail so that the fuel injectors come straight out of their ports.
9. Inspect injector O-rings upon removal and discard any that appear damaged or worn.
10. Cover fuel injector ports while injectors are removed.
INSTALLATION
Fuel Rail And Injector Assembly:
1. Be certain injectors are seated into receiver cups and retainer rings are in place before attempting to install fuel rail assembly.
2. Install injector wiring harness and fasten into wiring clips. Make sure injector ports are clean and any plugs have been removed.
3. Lube injector O-rings with clean motor oil and install the injector/rail assembly into the injector ports. Install the 2 fuel rail mounting bolts and ground straps. (Make sure fuel rail seats evenly with all injectors seated in their ports.) Torque mounting bolts to 200 lb-in (22.5 Nm).
4. Reconnect detonation (knock) sensor electrical connector.
Fuel Rail And Fuel Pressure Regulator:
5. Lube fuel pressure regulator O-ring with clean motor oil, and install fuel pressure regulator into fuel rail receiver cup. Install fuel pressure regulator attaching nuts and torque to 65 lb-in (7 Nm) Connect PCV hose harness and vacuum hose harness.
Fuel Hoses And Connectors:
6. Connect vacuum hose to fuel pressure regulator. Connect fuel return hose to fuel pressure regulator and torque tube nut to 250 lb-in (28 Nm).
7. Connect fuel supply and return hoses to fuel tube assembly and torque hose clamps to 1 Nm (10 lbs.in.). Connect fuel injector harness electrical connector, and install air cleaner. Connect negative battery cable.
8. Pressurize fuel system and check for leaks. [1][2]Fuel Pressure Leak Down Test