Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 43178 Fuel Line Disconnect Tool

REMOVAL PROCEDURE




1. Remove the 2 fasteners.
2. Remove the 2 plastic retainers.
3. Remove the engine cover (1) from the engine.
4. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure.
5. Remove the quick connect coupling cover.




6. Disconnect the coupling for the fuel feed hose from the fuel feed pipe of the fuel rail using the J 43178. Use a shop towel in order to catch any remaining fuel that may leak.




7. Disconnect the breather hose from the cylinder head (1).




8. Disconnect the four electrical connectors (1) from the fuel injectors.
9. Release the three clamps (2) from the fuel injector wire harness.
10. Lift the fuel injector wire harness up and away from the fuel rail.




11. Remove the fastener (2) from the fuel pipe bracket.
12. Remove the fasteners (1) from the fuel rail (7).
13. Remove the fuel rail (7) and the spacers (3) from the engine.
14. Remove the fuel injectors (5) with the O-rings (6) and with the grommets (4).

INSTALLATION PROCEDUREs




1. Install new O-rings (6) and new grommets (4) on the fuel injectors (5).
2. Apply clean engine oil to the O-rings (6) and to the grommets (4).
3. Install the fuel injectors (5) into the fuel rail.
4. Install the fuel rail (7) and the spacers (3) onto the engine.
5. Secure the fuel rail to the engine with the 2 fasteners (1).

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the fasteners to 19 N.m (13 lb ft).

6. Install the fastener (2) to the fuel pipe bracket.

Tighten the fastener to 9 N.m (80 lb in).




7. Secure the fuel injector wire harness to the engine with the three clamps (2).
8. Connect the fuel injector electrical connectors (1) to the four fuel injectors.




9. Connect the PCV breather hose (1) to the cylinder head cover.




10. Connect the quick-connect fitting (1) for the fuel feed hose to the fuel feed pipe (2) of the fuel rail.
11. Install the quick connect coupling cover.
12. Connect the negative battery cable.

Tighten the two battery cable fasteners to 15 N.m (11 lb in).

13. Turn ON the ignition in order to pressurize the fuel system.
14. Turn OFF the ignition.
15. Inspect for fuel leaks.
16. Repair any fuel leaks as necessary.




17. Install the engine cover (1).
18. Secure the engine cover (1) with the 2 fasteners.

Tighten the two fasteners to 7 N.m (62 lb in).

19. Install the 2 plastic retainers.