Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
NOTE:
- Refer to Fuel Rail Notice in Service Precautions.
- Refer to Cover and Plug Openings Notice in Service Precautions.
IMPORTANT:
- When servicing the fuel rail assembly, take precautions to prevent dirt and other contaminants from entering the fuel passages. Cap the fittings and plug the holes during servicing.
- Always maintain cleanliness when servicing fuel system components.
1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Release.
2. Clean the fuel rail assembly and the connections.
3. Disconnect the fuel feed pipe (2) and the fuel return pipe (1) from the fuel rail.
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 the supercharger.
6. Remove the generator brace.
7. Remove the bypass valve actuator.
8. Disconnect the fuel injector electrical connectors.
9. Remove the fuel injector electrical harness clips holding harness to front and the rear of the fuel rail.
10. Remove the engine mount strut bolt and nut from the left engine mount strut.
11. Reposition the wiring harness from the left engine mount strut bracket.
12. Remove the fuel rail hold-down nuts.
13. Remove the fuel rail hold-down stud.
14. 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.
1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean engine oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.
5. Install the fuel rail hold-down nuts.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the nuts to 10 N.m (89 lb in).
6. Install the fuel rail-hold down stud.
Tighten
Tighten the stud to 25 N.m (18 lb ft).
7. Install the wiring harness to the engine mount strut.
8. Install the left engine mount strut bolt and nut.
Tighten
Tighten the nut to 48 N.m (35 lb ft).
9. Install the fuel injector electrical harness clips holding harness to the front and the rear of fuel rail.
10. Connect the fuel injector electrical connectors.
11. Install the bypass valve actuator.
12. Install the rear generator mounting bracket and generator.
13. Install the ignition coil wires to the coil, and the retainer clips to the top of super charger.
14. Connect the vacuum line to the fuel pressure regulator.
15. Connect the fuel feed pipe (2) and the fuel return pipe (1) to the fuel rail.
16. Connect the negative battery cable.
17. Inspect for leaks.
17.1. Turn ON the ignition for 2 seconds.
17.2. Turn OFF the ignition for 10 seconds.
17.3. Turn ON the ignition.
17.4. Inspect for fuel leaks.
18. Install the fuel injector sight shield.