Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTTOOLS REQUIRED
J 37088-A Fuel Line Quick-Connect Separator
REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
NOTE: Refer to Cover and Plug Openings Notice in Service Precautions.
IMPORTANT: Always maintain cleanliness when servicing fuel system components.
2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed and fuel return pipes from the fuel rail tubes. Refer to Quick Connect Fitting(s) Service (Metal Collar).
4. Remove the fuel injector coil wires.
5. Remove the vacuum line from the vacuum source to the fuel pressure regulator.
6. Remove the Manifold Absolute Pressure (MAP) sensor electrical connector.
7. Remove the vacuum line to the vacuum switch from the fuel pipe bundle.
8. Remove the vacuum source from the intake manifold.
9. Remove the fuel injector electrical connectors.
10. Remove the fuel injector harness fasteners.
11. Remove the fuel rail hold-down bolts.
12. Remove the fuel rail with equal force on both sides of the fuel rail.
13. Remove the front fuel injector retaining clips on each side of the fuel rail.
14. Remove the front fuel injector on each side of the fuel rail. The fuel rail will now clear the intake manifold.
INSTALLATION PROCEDURE
CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.
NOTE: Refer to Fuel System Ground Notice in Service Precautions.
1. The O-rings must be replaced on all components that are replaced.
2. Lightly oil the fuel injector O-rings with clean engine oil.
NOTE:
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
^ Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
^ Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.
3. Without the front fuel injectors on either side of the fuel rail, place the fuel rail assembly on the intake manifold.
4. Install the front fuel injector on each side of the fuel rail.
5. Install the fuel injector retaining clips on the front fuel injector on each side of the fuel rail.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Seat the fuel injectors by HAND.
Tighten
Tighten the fuel rail hold-down bolts to 10 N.m (89 lb in).
7. Connect the fuel injector harness fasteners.
8. Connect the fuel injector electrical connectors.
9. Install the vacuum source to the intake manifold.
10. Install the vacuum line to the vacuum switch from the fuel pipe bundle.
11. Install the vacuum line from the vacuum source to the fuel pressure regulator.
12. Connect the fuel feed and fuel return pipes by pushing the pipes onto the fuel rail tubes.
13. Connect the MAP sensor electrical connector.
14. Connect the fuel injector coil wires.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
15. Reconnect the negative battery cable.
16. Inspect for leaks with the following procedure:
16.1. Turn ON the ignition for 2 seconds.
16.2. Turn OFF the ignition for 10 seconds.
16.3. Turn ON the ignition.
16.4. Check for fuel leaks.