Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE

NOTE: Refer to Cover and Plug Openings Notice in Service Precautions.

IMPORTANT:
^ 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.
^ Always maintain cleanliness when servicing fuel system components.




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 (1) and return pipes (2) from the fuel rail tubes.





4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires.




6. Disconnect the 6 injector electrical connectors.




7. Remove the fuel rail hold-down bolts.
8. 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 motor 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 bolts.

Tighten
Torque the fuel rail hold-down bolts to 10 N.m (89 lb in).




6. Connect the 6 fuel injector electrical connectors.




7. Connect the fuel feed (1) and return (2) pipes to the fuel rail tubes.




8. Connect the vacuum line to the fuel pressure regulator.
9. Install the ignition coil wires.
10. Tighten the fuel fill cap.
11. Connect the negative battery cable.
12. Inspect for leaks,
12.1. Turn ON the ignition for 2 seconds.
12.2. Turn OFF the ignition for 10 seconds.
12.3. Turn ON the ignition.
12.4. Inspect for fuel leaks.
13. Install the fuel injection sight shield.