Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE

NOTE:
- Refer to Fuel Rail Notice in Service Precautions.
- Refer to Cover and Plug Openings Notice in Service Precautions.

IMPORTANT:
- When servicing the fuel rail assembly, take precautions to prevent dirt and other contaminants from entering the fuel passages. Cap the fittings and plug the holes during servicing.
- Always maintain cleanliness when servicing fuel system components.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Clean the fuel rail assembly and the fuel feed pipe.
3. Disconnect the fuel feed pipe (1) from the fuel rail.
4. Remove the generator brace.




5. Disconnect the fuel injector electrical connectors.




6. Remove the fuel injector electrical harness clips holding harness to front and the rear of the fuel rail.




7. Unclip and remove the spark plug wires from the fuel rail retaining clips.
8. Disconnect and reposition the spark plug wires from the ignition control module.
9. Remove the fuel rail hold-down nuts (2).
10. Remove the fuel rail (1) with the fuel injectors (3) 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.





1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean engine oil.
3. Place the fuel rail (1) with the fuel injectors (3) on the intake manifold.
4. Seat the fuel injectors (3) by HAND.
5. Install the fuel rail hold-down nuts (2).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the nuts to 10 N.m (89 lb in).

6. Reposition and connect the spark plug wires to the ignition control module.
7. Install the spark plug wires to the fuel rail retaining clips.




8. Install the fuel injector electrical harness clips holding harness to the front and the rear of fuel rail.




9. Connect the fuel injector electrical connectors.
10. Install the generator brace.




11. Connect the fuel feed pipe (1) to the fuel rail.
12. Connect the negative battery cable.
13. Inspect for leaks.
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.
14. Install the fuel injector sight shield.