Fuel Rail: Service and Repair
REMOVALThrottle Body Removal And Replacement:
1. Fuel system pressure must be released prior to service. Service and Repair
2. Disconnect negative battery cable and remove air cleaner assembly.
Throttle Cable Attachment To Throttle Body:
3. Disconnect the throttle cable from the throttle body. Remove the wiring harness from the intake manifold water tube and the throttle cable bracket.
4. Disconnect the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors from the throttle body.
5. Disconnect the fuel injector wiring harness electrical connector from the main engine harness.
6. Remove the vacuum harness from the throttle body.
Electrical And Vacuum Connections To Intake Manifold:
7. Remove the brake booster and PCV vacuum hoses from the air intake plenum. Remove the EGR tube flange from intake manifold (if equipped).
8. Disconnect the Charge Temperature Sensor electrical connector and remove the vacuum harness from the air intake plenum.
9. Remove the cylinder head to air intake plenum strut.
Manifold Absolute Pressure (MAP) Sensor Location (Back Of Intake Plenum):
10. Disconnect the MAP sensor and heated oxygen sensor electrical connectors, and remove the engine mounted ground strap.
11. Disconnect the Quick-Connect fuel fittings by pushing in on the black retainer ring located at the end of each fitting. Slide the fuel fittings off of the chassis fuel tube.
WARNING: Wrap the fuel lines with a shop towel so that any spilled fuel will be absorbed.
Ignition Coil Packs:
12. Disconnect the DIS coil pack electrical connector.
13. Remove the 4 DIS coil pack mounting bolts and remove the coil pack from the engine. Remove the alternator bracket to intake manifold bolt.
Fig 1 Intake Plenum Mounting Bolts:
14. Remove the 4 air intake plenum mounting bolts, and rotate the intake plenum over the rear valve cover.
Fuel Rail Removal And Replacement (Intake Plenum Removed):
15. Cover the lower intake manifold while servicing the fuel injectors.
16. Disconnect vacuum hose from the fuel pressure regulator.
Fuel Rail Attaching Bolts:
17. Remove the fuel tube retainer bracket screw and the fuel rail attaching bolts. Spread the retainer bracket to allow for fuel tube removal clearance.
Fuel Tube Retainer Bracket:
18. Remove the fuel rail wiring harness clip from the alternator bracket.
19. Disconnect the cam position sensor, coolant temperature sensor, and engine temperature sensor electrical connectors.
Fuel Rail Removal And Replacement (Intake Plenum Removed):
20. Remove fuel rail from engine. Be careful not to damage the fuel injector O-rings when pulling the injectors out of the ports in the lower intake manifold.
INSTALLATION
1. Check that the injector holes are clean and that all protective plugs have been removed. Replace any O-rings if damaged.
2. Lube the injector O-rings with clean engine oil and install the fuel injectors into their respective holes.
Fuel Rail Attaching Bolts:
3. Push the fuel injectors into their holes until they are fully seated. Install the 4 fuel rail mounting bolts and torque to 200 lb-in (22.5 Nm)
4. Install fuel tube retaining bracket screw and torque to 35 lb-in (4 Nm).
5. Connect the cam position sensor, coolant temperature sensor, and engine temperature sensor electrical connectors.
Fuel Tube Retainer Bracket:
6. Connect the fuel injector wiring harness clips to the alternator bracket and the intake manifold water tube.
7. Connect the vacuum line to the fuel pressure regulator.
8. Remove the protective covering on the lower intake manifold and clean the surface. Install the intake manifold gasket to the lower intake manifold.
9. Install the air intake plenum onto the lower intake manifold and tighten the mounting bolts finger tight.
10. Install the alternator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. Tighten finger tight.
Fig 1 Intake Plenum Mounting Bolts:
11. Torque the manifold bolts to 250 lb-in (28 Nm), following the torque sequence shown.
12. Torque the alternator bracket to intake manifold bolt to 40 lb-ft (54 Nm).
13. Torque the cylinder head to intake manifold strut bolts to 40 lb-ft (54 Nm).
Manifold Absolute Pressure (MAP) Sensor Location (Back Of Intake Plenum):
14. Connect the ground wire, MAP sensor, and oxygen sensor electrical connectors.
Electrical And Vacuum Connections To Intake Manifold:
15. Connect the PCV system, the vacuum harness to the intake plenum, the power brake booster, and the charge temperature sensor electrical connector. Connect the EGR tube flange to the intake manifold and torque to 200 lb-in (22 Nm) (if equipped).
16. Connect the wiring harness into the hole in the throttle cable bracket.
17. Connect the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors to their respective components on the throttle body.
18. Connect the vacuum harness to the throttle body.
19. Install the DIS coil pack, and torque the 4 mounting bolts to 105 lb-in (12 Nm).
20. Connect the Quick-Connect fuel fittings to the chassis tubes. Push the fittings until they make a "click" noise. Pull on the fittings to make sure that they are securely locked into place. The fuel return fitting is 1/4 inch and the fuel supply fitting is 5/16 inch.
21. Install throttle cable. Service and Repair
22. Install air inlet hose and air cleaner assembly.
23. Connect negative battery cable.
24. Pressurize fuel system and check for leaks. [1][2]Fuel Pressure Leak Down Test