Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
NOTE:
^ Refer to Fuel Rail Notice in Service Precautions.
^ Refer to Cover and Plug Openings Notice in Service Precautions.
1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure.
2. Clean the fuel rail assembly and connections.
3. Disconnect the fuel feed pipe (2) and return pipe (1) from the fuel rail. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
6. Remove the generator and rear generator mounting bracket.
7. Remove the bypass valve actuator.
8. Disconnect the fuel injector electrical connectors.
9. Remove the fuel injector electrical harness clips holding harness to front of fuel rail.
10. Remove the fuel rail hold-down nuts.
11. Remove the fuel rail hold down stud.
12. Remove the fuel rail with equal force on both sides of the fuel rail.
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.
NOTE: Refer to Fuel Rail Notice in Service Precautions.
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 assembly on the intake manifold.
4. Seat the fuel injectors by HAND.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Install the fuel rail hold-down nuts.
Tighten
Tighten the fuel rail hold-down nuts to 10 N.m (89 lb in).
6. Install the fuel rail hold down 1 stud 1.
Tighten
Tighten the fuel rail hold-down stud to 25 N.m (18 lb ft).
7. Install the bypass valve actuator.
8. Install the rear generator mounting bracket and generator.
9. Connect the fuel injector electrical harness clips holding harness to front of fuel rail.
10. Connect the fuel injector electrical connectors.
11. Install the ignition coil wires to coil and retainer clips on top of super charger.
12. Connect the vacuum line to the fuel pressure regulator.
13. Connect the fuel teed pipe (2) and return pipe (1) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Plastic Collar).
14. Connect the negative battery cable.
15. Inspect for leaks.
15.1. Turn ON the ignition for 2 seconds.
15.2. Turn OFF the ignition for 10 seconds.
15.3. Turn ON the ignition.
15.4. Inspect for fuel leaks.
16. Install the fuel injector sight shield.