Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTTOOLS REQUIRED
J 43013 Fuel Injector Removal Tool
REMOVAL PROCEDURE
NOTE: Refer to Cover and Plug Openings Notice in Service Precautions.
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. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
2. Clean the fuel rail assembly and connections.
3. Disconnect the fuel teed, (1) and return pipes (2) from the fuel rail tubes. Refer to Quick Connect Fitting(s) 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.
Fuel Rail Assembly:
7. Remove the fuel rail hold-down bolts.
8. Carefully raise the injectors using the J 43013.
9. 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: Refer to Fuel Rail Notice in Service Precautions.
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. Install the fuel rail hold down bolts.
Tighten
Torque the fuel rail hold-down bolts to 10 N.m (89 lb ft).
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. Install the ignition coil wires.
10. Tighten the fuel fill cap.
11. Connect the negative battery cable.
12. Inspect for leaks.
12.1. Turn the ignition switch ON for 2 seconds.
12.2. Turn the ignition switch OFF for 10 seconds.
12.3. Turn the ignition switch ON.
12.4. Check for fuel leaks.
13. Install the fuel injection sight shield.