Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

Notice:
* 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.


Notice: 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: When servicing the fuel rail, take precautions to prevent dirt and other contaminants from entering the fuel passages. Cap the fittings during servicing.


Important: Always maintain cleanliness when servicing fuel system components.






1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027)).
2. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




3. Remove the positive crankcase ventilation (PCV) tube from the intake duct and intake manifold.




4. Disconnect the spark plug wires from the ignition coils.
5. Remove the spark plug wire retainer from the fuel rail.




6. Disconnect the engine harness electrical connector (1) from the throttle actuator.
7. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor.




8. Disconnect the engine harness electrical connector (1) from the ignition control module wiring harness electrical connector (2).
9. Disconnect the engine harness electrical connector (3) from the manifold absolute pressure (MAP) sensor.




10. Disconnect the front engine harness electrical connectors (1) from the fuel injectors.
11. Remove the front engine harness retainers (2) from the fuel rail.




12. Remove the engine harness retainers (1, 3) from the heat shield.
13. Disconnect the engine harness electrical connector (2) from the exhaust gas recirculation (EGR) valve.
14. Disconnect the engine harness electrical connector (4) from the evaporative emission (EVAP) solenoid.




15. Disconnect the engine harness electrical connector from the heated oxygen sensor (HO2S) pigtail.




16. Disconnect the rear engine harness electrical connectors (1) from the fuel injectors.
17. Remove the rear engine harness retainers (2) from the fuel rail.
18. Gather the engine harness branches and reposition them out of the way.




19. Remove the fuel rail nuts.
20. Gently lift the fuel rail up with equal force on both sides of the fuel rail.




21. If replacing the fuel rail, perform the following steps otherwise proceed to step 6 in the installation procedure.
22. Remove the fuel injector retainers (1).
23. Remove the fuel injectors (3).
24. Remove and discard the fuel injector upper O-ring seals (2).
25. Remove and discard the fuel injector lower O-ring seals (4).


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.

Notice:
* 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. If replacing the fuel rail, perform the following steps otherwise proceed to step 6.
2. Lubricate the NEW O-ring seals with clean engine oil.
3. Install the NEW fuel injector upper and lower O-ring seals (2, 4) onto the injectors.
4. Install the fuel injectors (3).
5. Install the fuel injector retainers (1).




6. Lubricate the lower fuel injector O-ring seals with clean engine oil.
7. Place the fuel rain into position and seat the fuel injectors by gently pressing down over the injectors.

Notice: Refer to Fastener Notice (Fastener Notice).

8. Install the fuel rail nuts.

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




9. Position the engine harness over the engine.
10. Install the engine harness retainers (2) to the fuel rail.
11. Connect the engine harness electrical connectors (1) to the fuel injectors.




12. Connect the engine harness electrical connector to the HO2S pigtail.




13. Install the engine harness retainers (1, 3) to the heat shield.
14. Connect the engine harness electrical connector (2) to the EGR valve.
15. Connect the engine harness electrical connector (4) to the EVAP solenoid.




16. Install the engine harness retainers (2) to the fuel rail.
17. Connect the engine harness electrical connectors (1) to the fuel injectors.




18. Connect the engine harness electrical connector (3) to the MAP sensor.
19. Connect the engine harness electrical connector (1) to the ignition control module wiring harness electrical connector (2).




20. Connect the engine harness electrical connector (2) to the ECT sensor.
21. Connect the engine harness electrical connector (1) to the throttle actuator.




22. Install the spark plug wire retainer to the fuel rail.
23. Connect the spark plug wires to the ignition coils.




24. Install the PCV tube to the intake duct and intake manifold.




25. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
27. 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.

28. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Service and Repair).