Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE
An eight digit identification number is stamped on the left hand fuel rail, fueling even cylinders 2, 4, 6. Refer to this number if servicing or part replacement is required.

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: 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.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the upper intake manifold.
3. Remove the engine compartment fuel pipe retainer bolt.
4. Disconnect the engine fuel feed pipe at the fuel rail.




5. Disconnect the engine fuel return pipe at the fuel pressure regulator.
6. Remove the fuel feed pipe and fuel return pipe O-rings and discard.
7. Disconnect the main injector harness electrical connector.
8. Disconnect the connectors from the fuel injectors using the procedures in steps 8 and 9.




9. Pull up the lock release (2) of the fuel injector connector.




10. Depress the lock tab (1) and lift the connector from the injector.
11. Remove the injector harness from the fuel rail.




12. Disconnect the coolant temperature sensor electrical connector.




13. Remove the fuel rail attaching bolts.
14. Remove the fuel rail assembly.
15. Remove the injector O-ring seal from the spray tip end of each injector. Discard the seals.

INSTALLATION PROCEDURE

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. Install the fuel rail assembly into the intake manifold. Tilt the rail assembly to install the injectors.
2. Install the fuel rail attaching bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the fuel rail attaching bolts to 10 N.m (89 lb in).




3. Connect the coolant temperature sensor electrical connector.
4. Install the injector electrical harness to the fuel rail.




5. Connect the injector electrical connectors.
6. Push the slide locks (2) into the locked position.
7. Connect the main injector harness electrical connector.
8. Install the new O-rings on the fuel feed pipe and fuel return pipe.




9. Connect the fuel feed pipe to the fuel rail.

Tighten the fuel feed pipe fitting to 17 N.m (13 lb ft).




10. Connect the fuel return pipe to the fuel pressure regulator.

Tighten the fuel return pipe fitting to 17 N.m (13 lb ft).

11. Install the engine compartment fuel pipe retainer bolt.

Tighten the fuel pipe retainer bolt to 25 N.m (18 lb ft).

12. Install the upper intake manifold.
13. Connect the negative battery cable.
14. Inspect for fuel leaks using the following procedure:
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.