Fuel Rail: Service and Repair

REMOVAL PROCEDURE





An eight digit identification number is stamped on the left hand fuel rail (fueling even cylinders 2,4,6), Refer to this number if servicing or part replacement is required).

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.

IMPORTANT: Important when servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the upper intake manifold.
3. Disconnect the engine fuel feed pipe at fuel rail.




4. Disconnect the engine fuel return pipe at the fuel pressure regulator.
5. Remove the fuel teed pipe and fuel return pipe O-rings and discard.




6. Disconnect the main injector harness electrical connector.




7. Disconnect the coolant temperature sensor electrical connector.




8. Remove the fuel rail retaining bolts.
9. Remove the fuel rail assembly.




10. Disconnect the injector electrical connectors.
11. Remove the injector electrical harness from the fuel rail.
12. Remove the injector O-ring seal from spray tip end of each injector. Discard seals. With the O-ring removed, the O-ring backup may slip off of the injector. Be sure to retain the O-ring backup for reuse.

INSTALLATION PROCEDURE





NOTE:
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
^ Do not use the 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. Reinstall the injector electrical harness to the fuel rail.
2. Connect the injector electrical connectors.
3. Ensure that O-ring backups are on injectors before installing new O-rings. Lubricate new injector O-ring seals with clean engine oil and install on spray tip end of each injector.




4. Reinstall The fuel rail assembly into the intake manifold. Tilt rail assembly to install injectors.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Reinstall the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attaching bolt to 10 N.m (7 lb ft).




6. Connect the coolant temperature sensor electrical connector.




7. Connect the main injector harness electrical connector.
8. Reinstall the new O-rings on fuel teed pipe and fuel return pipe.




9. Reinstall the fuel feed pipe at the fuel rail.

Tighten
Tighten the engine fuel pipe nut to 17 N.m (13 lb ft).




10. Connect the fuel return pipe at the fuel pressure regulator.

Tighten
Tighten the engine fuel pipe nut to 17 N.m (13 lb ft).

11. Reinstall the upper intake manifold.
12. Tighten the fuel filler cap.
13. Reconnect the negative battery cable.
14. Check for fuel leaks.
14.1. Turn the ignition switch ON for 2 seconds.
14.2. Then the ignition switch OFF for 10 seconds.
14.3. Turn the ignition switch ON.
14.4. Check for fuel leaks.