Fuel Rail: Service and Repair
REMOVAL PROCEDURE
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.
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. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed, (2) and return pipes (1) from the fuel rail tubes.
4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
6. Remove the generator and rear generator mounting bracket.
7. Remove the bypass valve actuator.
8. Disconnect the (6) fuel injector electrical connectors.
9. Remove the fuel injector electrical harness clips holding harness to front of fuel rail.
10. Remove the fuel rail hold-down bolts (4).
11. Remove the fuel rail hold down stud (1).
12. Remove the fuel rail with equal force on both sides of the fuel rail.
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 serviced.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Reinstall the fuel rail hold-down bolts (4).
Tighten
Tighten the fuel rail hold-down bolts to 10 N.m (7 lb ft).
6. Reinstall the fuel rail hold down stud (1).
Tighten
Tighten the fuel rail hold-down stud to 25 N.m (18 lb ft).
7. Reinstall the bypass valve actuator.
8. Reinstall the rear generator mounting bracket and generator.
9. Connect the fuel injector electrical harness clips holding harness to front of fuel rail.
10. Connect the (6) fuel injector electrical connectors.
11. Reinstall the ignition coil wires to coil and retainer clips on top of super charger.
12. Connect the vacuum line to the fuel pressure regulator.
13. Connect the fuel feed, (2) and return pipes (1) to the fuel rail tubes.
14. Tighten the fuel fill cap.
15. Reconnect the negative battery cable.
16. Inspect for leaks.
16.1. Turn the ignition switch ON for 2 seconds.
16.2. Turn the ignition switch OFF for 10 seconds.
16.3. Turn the ignition switch ON.
16.4. Check for fuel leaks.
17. Install the fuel injection sight shield.