Fuel Rail: Service and Repair

SPECIAL SERVICE TOOLS

REMOVAL

WARNING
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED RESULTING IN POSSIBLE PERSONAL INJURY
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING.
^ BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED.

1. Remove the throttle body spacer.
- Perform Fuel Pressure Release procedure.






2. Disconnect the RH radio capacitor assembly connector.







3. Disconnect the Exhaust Gas Recirculation (EGR) Vacuum Regulator (EVR).
1 Disconnect the electrical connector.
2 Disconnect the vacuum line.







4. Remove the bolts and the bracket assembly.







5. Disconnect the Fuel Pressure Regulator vacuum hose.







6. Remove the fuel line tether clamps.







7. Using the (A) and (B) Spring Lock Coupling Disconnect tools, disconnect the fuel lines.







8. Remove and discard the fuel line O-rings.







9. Disconnect the five RH fuel injector electrical connectors.







10. Disconnect the five LH fuel injector electrical connectors.







11. Remove the crankcase vent connector and hose.







12. Remove the bolts.







13. Remove the fuel injectors.
1 Lift the fuel supply manifold.
2 Remove the injectors.







14. Remove and discard the O-rings from each fuel injector.
15. Shift and remove the fuel injection supply manifold.

INSTALLATION

CAUTION: Check for fuel leakage after installation is complete.

NOTE: Be sure fuel injectors and fuel injection supply manifold are fully seated.












1. Follow the removal procedure in reverse order.

NOTE: Lubricate the new O-rings with engine oil.