Fuel Rail: Service and Repair
REMOVAL PROCEDUREAn eight digit identification number is stamped on the left hand fuel rail (fueling even cylinders 2,4,6). Refer to this number it 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.
IMPORTANT: Important when servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.
1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the upper intake manifold.
3. Disconnect the engine fuel feed pipe at fuel rail.
4. Disconnect the engine fuel return pipe at the fuel pressure regulator.
5. Remove the fuel feed pipe and fuel return pipe O-rings and discard.
6. Disconnect the main injector harness electrical connector.
7. Pull up the lock release of the fuel injector connector (1).
8. Depress the lock tab (1) and lift the connector from the injector.
9. Remove the injector electrical harness from the fuel rail.
10. Disconnect the coolant temperature sensor electrical connector.
11. Remove the fuel rail retaining bolts.
12. Remove the fuel rail assembly.
13. Remove the injector O-ring seal from spray tip end of each injector.
INSTALLATION PROCEDURE
NOTE
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector O-rings. 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.
1. Install The fuel rail assembly into the intake manifold. Tilt rail assembly to install injectors.
NOTE: Refer to Fastener Notice in Service Precautions.
2. Install the fuel rail attaching bolts.
Tighten
Tighten the fuel rail attaching bolt to 10 N.m (7 lb ft).
3. Connect the coolant temperature sensor electrical connector.
4. Install the injector electrical harness to the fuel rail.
5. Connect the injector connectors (2).
6. Push the slide locks (1) into position.
7. Connect the main injector harness electrical connector.
8. Install the new O-rings on fuel feed pipe and fuel return pipe.
9. Install the fuel feed pipe at the fuel rail.
Tighten
Tighten the fuel feed pipe nut to 17 N.m (13 lb ft).
10. Connect the fuel return pipe at the fuel pressure regulator.
Tighten
Tighten the fuel return pipe nut to 17 N.m (13 lb ft).
11. Install the upper intake manifold.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
12. Connect the negative battery cable.
13. Inspect for fuel leaks using the following procedure:
13.1. Turn ON the ignition, for 2 seconds.
13.2. Turn OFF the ignition, for 10 seconds.
13.3. Turn ON the ignition.
13.4. Inspect for fuel leaks.