Fuel Rail: Service and Repair
REMOVALWARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE SERVICING THE FUEL RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.
To release fuel pressure, refer to the Fuel System Pressure Release Procedure.
Fig. 19 Fuel Rail Assembly - Typical:
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connecting hose (Fig. 19). Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose.
1. Remove engine cover.
2. Remove negative battery cable at battery.
3. Remove air cleaner.
4. Perform the fuel pressure release procedure.
5. Remove throttle body from intake manifold. Refer to Throttle Body removal.
Fig. 20 A/C Compressor Support Bracket - Typical:
6. If equipped with air conditioning, remove the A-shaped A/C compressor-to-intake manifold support bracket (three bolts) (Fig. 20).
Fig. 21 Fuel Injector Connectors - Typical:
7. Disconnect electrical connectors at all fuel injectors (Fig. 21). The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification.
8. Disconnect fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures,
9. Remove the remaining fuel rail mounting bolts.
10. Clean dirt/debris from each fuel injector at intake manifold.
11. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold.
12. Remove fuel rail (with injectors attached) from engine.
Fig. 22 Fuel Injector Mounting - Typical:
Fig. 23 Injector Retaining Clips - Typical Injector:
13. Remove the clip(s) retaining the injector(s) to fuel rail (Fig. 22) or (Fig. 23).
INSTALLATION
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE SERVICING THE FUEL RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.
To release fuel pressure, refer to the Fuel System Pressure Release Procedure.
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the rail halves at the connecting hose (Fig. 19). Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose.
1. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
2. Install injector(s) and injector clip(s) to fuel rail.
3. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
4. Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.
5. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder.
6. Install fuel rail mounting bolts.
7. Connect electrical connector to intake manifold air temperature sensor.
8. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged.
9. Install the A/C support bracket (if equipped).
10. Install throttle body to intake manifold. Refer to Throttle Body installation.
11. Install fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures.
12. Install air cleaner.
13. Connect battery cable to battery.
14. Start engine and check for leaks.
15. Install engine cover.