Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

Caution: Refer to Fuel Rail Caution (Fuel Rail Caution).

Caution: 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.

Note: 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.

Note: Always maintain cleanliness when servicing fuel system components.




1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).
2. Clean the fuel rail assembly and the fuel feed pipe.
3. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
4. Remove the spark plug wires from the fuel rail.
5. Disconnect and reposition the spark plug wires from the ignition control module.




6. Disconnect the fuel injector electrical connectors.




7. Remove the fuel rail hold-down nuts (2).
8. Remove the fuel rail (1) with the fuel injectors (3) with equal force on both sides of the fuel rail.

Installation Procedure

Warning

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.

Caution: Refer to Fuel Rail Caution (Fuel Rail Caution).




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.

Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the fuel rail hold-down nuts (2).

Tighten the nuts to 10 Nm (89 lb in).




6. Connect the fuel injector electrical connectors.
7. Reposition the spark plug wires to the fuel rail.
8. Connect the spark plug wires to the ignition control module.




9. Connect the fuel feed pipe (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
10. Tighten the fuel fill cap.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (L26) (Service and Repair)Battery Negative Cable Disconnection and Connection (LS4) (Service and Repair).
12. 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.

13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).