Fuel Rail: Service and Repair
REMOVAL PROCEDURE
TOOLS REQUIRED
^ J 34730 Fuel Pressure Gauge
^ J 41081 Fuel Injector Remover
^ J 37088-A Fuel Line Quick Connect Separator
NOTE:
^ Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the IAT sensor connector (1) from the IAT sensor.
3. Remove the fuel rail end-point bracket (1) retainer bolt (2) from the bracket.
Description:
4. Remove the EGR pipe at throttle body spacer.
5. Remove the brake booster vacuum hose at intake manifold vacuum fitting.
6. Remove the front bank spark plug wires.
Description:
7. Disconnect the Mass Air Flow (MAF) sensor (5) electrical connector (2) from the MAF sensor.
8. Remove the MAF sensor.
9. Disconnect the injector electrical connectors. Lay the harness aside.
10. Remove the fuel rail ground wire (7) at rear cylinder head.
11. Remove the fuel pressure regulator (1) from the fuel rail.
12. Remove the crankcase ventilation vacuum hoses.
13. Remove the fuel line retainers (2), (3) at the quick connect fittings.
14. Disconnect the quick-connect fittings (2) at the fuel rail.
Description:
15. Remove the throttle body mount bolts.
16. Remove the throttle body.
17. Remove the throttle body spacer (3).
18. Remove the throttle body O-ring seal.
19. Release the locking tabs (8) on fuel rail by pushing toward center of intake manifold and pry each injector out of intake manifold using J 41081.
Fuel Rail Assembly And Intake Manifold:
20. Remove the fuel rail assembly from the intake manifold.
DISASSEMBLE PROCEDURE
Fuel Rail Assembly And Intake Manifold:
1. Remove the fuel injector harness.
2. Remove the clips (3) from the injectors (5) on the fuel rail.
3. Remove the upper (6) and lower (4) seals from the injectors. Discard seals.
ASSEMBLE PROCEDURE
Description:
1. Lubricate the upper (3) and lower (2) injector O-rings with clean oil and install on the O-rings on to the fuel injectors.
Fuel Rail Assembly And Intake Manifold:
2. Assemble the injectors to the fuel rail with new retainer clips.
3. Assemble the injector harness.
INSTALLATION PROCEDURE
Fuel Rail Assembly And Intake Manifold:
1. Reinstall the fuel rail with injectors on to the intake manifold.
Description:
2. Reinstall throttle body spacer (3).
3. Install the new throttle body O-ring seal,
4. Reinstall the throttle body (1).
5. Reinstall the throttle body mount bolts.
Tighten
Tighten the throttle body mount bolts to 12 N.m (106 lb in).
6. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet pipes.
7. Connect the quick-connect fittings to fuel rail.
8. Reinstall the fuel line retainers (2, 3) at the quick connect fittings.
Description:
9. Reinstall the fuel pressure regulator.
10. Reinstall the crankcase ventilation vacuum hoses.
11. Install the fuel rail ground wire at rear cylinder head (2).
Tighten
Tighten the fuel rail ground wire bolt to 11 N.m (97 lb in).
Fuel Rail Assembly And Intake Manifold:
12. Connect the injector harness and injector electrical connectors.
13. Reinstall the front bank spark plug wires.
14. Connect the brake booster vacuum hose at intake manifold vacuum fitting.
Description:
15. Connect the EGR pipe at throttle body spacer.
Tighten
Tighten the EGR pipe bolt to 28 N.m (21 lb in).
16. Install the fuel rail end-point bracket (1) retainer bolt (2).
Tighten
Tighten the bolt to 4 N.m (35 lb in).
17. Connect the IAT sensor connector (1) to the IAT sensor.
18. Reinstall the MAF sensor (2).
19. Connect the MAF sensor electrical connector to the MAF.
20. Tighten fuel filler cap (1).
21. Connect the negative battery cable.
22. Inspect for fuel leaks.
22.1. Turn the ignition switch ON for 2 seconds.
22.2. Turn the ignition switch OFF for 10 seconds.
22.3. Turn the ignition switch ON.
22.4. Check for fuel leaks.
23. Install the rear seat cushion.
24. Install the intake manifold sight shield.
Tighten
Tighten the nuts to 3 N.m (27 lb in).