Fuel Rail and Injector(S) Replacement
TOOLS REQUIRED^ SA9127E Gauge Bar Set
^ SA9805E Fuel Line Disconnect Set
REMOVAL
1. Disconnect negative battery cable.
2. Disconnect intake air temperature (IAT) sensor connector.
3. Loosen clamp at air cleaner assembly.
4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen clamp at throttle body assembly.
6. Disconnect PVC fresh air vent hose at cam cover.
7. Remove outlet resonator/duct assembly.
8. Place a shop rag over the throttle body assembly.
9. Using shop air, blow off dirt and dust near fuel injector ports.
CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER. PLACE CLOTH IN AN APPROVED CONTAINER.
10. Relieve fuel system pressure. (Refer to "Fuel System Pressure Relief".)
11. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
12. Position engine harness away from fuel rail assembly.
13. Disconnect fuel rail bracket and bolt at rear of cam cover.
NOTE: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
14. Disengage fuel transfer lines at quick contract from fuel line using Fuel Line Disconnect Set SA9805E (blue tool).
15. While supporting the fuel rail assembly with an open-end wrench, loosen transfer line fitting at fuel rail.
16. Position fuel line away from rail assembly without disconnecting de-gas hose.
17. Disconnect electrical connectors at fuel injectors.
18. Remove fuel rail assembly attachment bolts.
NOTE: Use care in removing fuel rail assembly to prevent damage to electrical terminals and spray tips. The fuel injector is serviced as a complete assembly only. Since it is an electrical component, it should not be immersed in any cleaner.
19. Remove fuel rail assembly by carefully pulling the rail backward and upward to remove injectors from cylinder head.
20. Move fuel rail assembly rearward while slightly rotating to remove fuel rail assembly.
NOTE:
^ When cleaning or servicing the fuel rail, care should be taken to ensure that the plastic fuel rail surfaces that mate to the fuel injector O-rings are not scratched.
^ Whenever the fuel rail is removed for service, upper and lower O-ring seals must be replaced. The injectors can be serviced individually if required.
21. Remove fuel injector(s) retaining clips.
22. Remove fuel injector(s) from fuel rail.
23. Remove and discard all injector O-ring seals by using a small pick.
INSTALLATION
1. Transfer components to new fuel rail if rail is being replaced.
2. Install new upper and lower O-ring seals to injectors.
3. Install injectors to fuel rail assembly.
4. Install isolators with new seals to injectors.
5. Install injector retaining clip.
IMPORTANT: Lubricate O-rings at injector isolators prior to installing injectors into cylinder head.
6. Install fuel rail to cylinder head.
7. Install fuel rail bolts.
Torque:
Fuel Rail Bolts: 10 N.m (89 in-lbs)
8. Re-position fuel line assembly.
NOTE: An open-end wrench must be used to support the fuel lines to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
9. Install fuel line bracket and bracket bolt.
Torque:
Transfer Line Fitting-to-Fuel Rail: 10 N.m (89 in-lbs)
10. Connect fuel rail bracket and bolt to cylinder head.
Torque:
Fuel Line Bracket Bolt: 10 N.m (89 in-lbs)
11. Connect fuel line to transfer tine.
NOTE: To assure proper connection and to fully seat the retaining tabs, lightly pull apart the connection.
12. Insert fuel transfer line into fuel line connection. An audible "click" noise should be heard.
13. Remove shop towel from throttle body.
14. Install outlet resonator/duct assembly into position.
15. Connect PCV fresh air bent hose assembly.
16. Tighten clamp at throttle body assembly.
17. Position outlet resonator/duct assembly up with support bracket and install push pin.
18. Tighten clamp at air cleaner assembly.
19. Connect intake air temperature (IAT) sensor connector.
20. Connect negative battery cable.