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. Service and Repair
2. Disconnect the IAT sensor connector (1) from the IAT sensor.




3. Remove the air cleaner intake duct (3).




4. Clean the fuel rail assembly and fuel pipe connections.
5. Remove the quick-connect fittings (2), (4) at the fuel rail.




6. Remove the fuel pressure regulator vacuum hose.




7. Remove the PCV air tube.




8. Remove the fuel rail end-point bracket retainer nut.




9. Remove the fuel injector electrical connectors from the fuel injectors.
10. Lay the harness aside.




11. Remove the bolts (2) from the fuel rail.
12. Raise the fuel injectors from the intake manifold with J 43013 fuel injector removal tool.

IMPORTANT: Store the fuel rail assembly in a clean secure location away from heat sources.

13. Lift the fuel rail and remove 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-ring in the proper position. If the upper and lower O-ring 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-ring are the same size but are made of different materials.

NOTE:
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector O-ring. 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.

IMPORTANT: Always use new upper and lower O-ring lightly coated motor oil.




1. Install the fuel rail assembly on to the intake manifold until the fuel injectors are fully seated.

NOTE: Refer to Fastener Notice in Service and Precautions.

2. Install the bolts (2) to the fuel rail assembly.

Tighten
Tighten the to bolts to 10 N.m (88 lb in).




3. Install the fuel injector electrical connectors to the fuel injectors.




4. Install the fuel rail end-point bracket retainer nut.

Tighten
Tighten the nut to 10 N.m (88 lb in).




5. Install the PCV air tube.




6. Install the fuel pressure regulator vacuum hose.




7. Install the quick-connect fittings (2), (4) at the fuel rail.




8. Install the air cleaner intake duct (3).
9. Install the MAF sensor electrical connector (1) to the MAF sensor (2).




10. Connect the IAT sensor connector (1) from the IAT sensor.

CAUTION: Refer to Battery Disconnect Caution in Service and Precautions.

11. Install 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. Visually inspect the fuel system for fuel leaks.




13. Tighten fuel filler cap (1).
14. Install the rear seat cushion.




15. Install the fuel injector sight shield (1) to the engine.
16. Install the fuel injector sight shield nuts (2).

Tighten
Tighten the nuts to 3 N.m (27 lb in).