Fuel Rail: Service and Repair

Removal Procedure
1. Relieve the fuel system pressure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions

2. Disconnect the negative battery cable.
3. Remove the intake manifold assembly.
4. Remove the fuel injector electrical connectors by pushing in the wire connector clip and pulling the electrical connector away from the fuel injector.
5. Remove the fuel feed inlet pipe at the rail (2). Refer to Quick Connect Fitting(s) Service (Plastic Collar).
6. Remove the fuel return pipe (3) from the pressure regulator.
7. Remove the fuel pressure regulator.
8. Remove the fuel rail attaching bolts.
9. Lift the fuel rail assembly from the cylinder head.




Installation Procedure

IMPORTANT: Lubricate the fuel injector O-rings with clean engine oil before installation.

1. Insert the fuel rail into the cylinder head.

NOTE: Refer to Fastener Note in Service Precautions.

2. Install the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attaching bolts to 24 N.m (18 lb ft).

3. Install the fuel pressure regulator.

IMPORTANT: Use a backup wrench on the fuel rail return fitting to prevent it from turning.

4. Install the fuel return pipe (3) to the fuel pressure regulator.

Tighten
Tighten fuel return pipe nut to 30 N.m (22 lb ft).

5. Install the fuel feed inlet pipe to the fuel rail (2). Refer to Quick Connect Fitting(s) Service (Plastic Collar).

IMPORTANT: Rotate the fuel injectors as required to avoid stretching the wire harness.

6. Install the fuel injector electrical connectors.
7. Install the intake manifold assembly.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

8. Reconnect negative battery cable.
9. Inspect for fuel leaks through the following steps:
1. Turn the ignition switch to the ON position for two seconds.
2. Turn the ignition switch to the OFF position for ten seconds
3. Turn the ignition switch to the ON position.
4. Check for fuel leaks.