Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 43013 Fuel Injector Remover

REMOVAL PROCEDURE

NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

IMPORTANT: Always maintain cleanliness when servicing fuel system components.




1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
2. Clean the fuel rail assembly and connections.
3. Disconnect the fuel feed, (1) and return pipes (2) from the fuel rail tubes.




4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires.




6. Depress the lock tab and disconnect the electrical connectors from the fuel injectors.




7. Remove the fuel rail hold-down bolts.
8. Carefully raise the injectors using the J 43013.
9. Remove the fuel rail with equal force on both sides of the fuel rail.

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 :
- 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.




1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the fuel rail hold down bolts.

Torque the fuel rail hold-down bolts to 10 N.m (89 lb in).




6. Connect the fuel injector electrical connectors to the fuel injectors.




7. Connect the fuel feed (1) and return (2) pipes to the fuel rail tubes.




8. Connect the vacuum line to the fuel pressure regulator.
9. Install the ignition coil wires.
10. Tighten the fuel fill cap.
11. Connect the negative battery cable.
12. Inspect for leaks.
1. Turn ON the ignition for 2 seconds.
2. Then OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.
13. Install the fuel injection sight shield.