Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENT
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.
NOTE: 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.
1. Disconnect the negative battery cable.
2. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Remove the upper intake manifold.
4. Remove the fuel pipe retainer clip bolt.
5. Remove the engine fuel feed pipe from the fuel rail.
6. Remove the engine fuel return pipe from the fuel pressure regulator.
7. Remove the fuel feed and the fuel return pipe O-rings, discard the O-rings.
8. Disconnect the main fuel injector wiring harness connector.
9. Pull up the lock release (2) on the fuel injector electrical connectors.
10. Depress the lock tabs (1) and disconnect the fuel injector electrical connectors.
11. Remove the fuel injector wiring harness from the fuel rail.
12. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
13. Remove the fuel rail bolts.
14. Remove the fuel rail assembly.
15. Remove the fuel injector O-ring seal from the spray tip end of each injector, discard the O-ring seals if damaged.
INSTALLATION PROCEDURE
NOTE:
- 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. Install the fuel injector O-ring seal to the spray tip end of each injector.
2. Lubricate O-ring seals with clean engine oil to aid in installation of the fuel injector rail.
3. Install the fuel rail assembly into the intake manifold. Tilt rail assembly to install injectors.
4. Install the fuel rail bolts.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten the bolts to 10 N.m (89 lb in).
5. Connect the ECT sensor electrical connector.
6. Install the fuel injector wiring harness to the fuel rail.
7. Connect the fuel injector electrical connectors.
8. Push the slide lock (2) into the locked position.
9. Connect the main fuel injector wiring harness electrical connector.
10. Install the new O-rings on the fuel feed and the fuel return pipe.
11. Install the fuel feed pipe to the fuel rail.
Tighten the engine fuel feed pipe nut to 17 N.m (13 lb ft).
12. Install the fuel return pipe to the fuel pressure regulator.
Tighten the engine fuel return pipe nut to 17 N.m (13 lb ft).
13. Install the fuel pipe retainer clip bolt.
Tighten the bolt to 25 N.m (18 lb ft).
14. Install the upper intake manifold.
15. Connect the negative battery cable.
16. Inspect for fuel leaks using the following procedure:
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.