Fuel Rail: Service and Repair

FUEL RAIL

Exploded View

EGR, PCV and Crankcase Vent Tube Connections:

Coolant Hose and Electrical Connectors:

Fuel Rail and Fuel Injectors:

Removal and Installation

WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install plugs to any open orifices or tubes. Failure to follow these instructions may result in fuel injection component damage.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Failure to follow these instructions may result in fuel or vapor leaks and connector damage.

1. Relieve the fuel pressure.
2. Disconnect the battery ground cable.
3. Remove the engine cover.
4. Remove the air cleaner and the air cleaner outlet tube.
5. Disconnect the fuel tube spring lock coupling.







6. Remove the exhaust manifold-to-EGR system module tube.
- To install, tighten to 40 Nm (30 lb-ft).

7. Remove the transmission fluid level indicator and tube bolt.
- To install, tighten to 28 Nm (21 lb-ft).







8. Remove the bolt and position the transmission fluid level indicator and tube aside.
- To install, tighten to 10 Nm (89 lb-in).







9. NOTE: The red clip must be pulled out before disconnecting the electrical connector.

Disconnect the electronic throttle body (TB) electrical connector.

10. Disconnect the fuel rail pressure and temperature sensor vacuum hose and the electrical connector.
11. Disconnect the quick connect coupling and remove the crankcase ventilation tube.
12. Disconnect the quick connect couplings and remove the PCV tube.
13. Disconnect and plug the PCV coolant hose.
14. Disconnect the 8 fuel injector electrical connectors.
15. Remove the 4 fuel rail stud bolts.
- To install, tighten to 10 Nm (89 lb-in).

16. Remove the fuel rail and the fuel injectors as an assembly.
17. Remove the fuel injectors from the fuel rail.

18. NOTE:
- Check for fuel leakage after installation is complete.
- Be sure the 8 fuel injectors and the fuel rail are fully seated.

To install, reverse the removal procedure.