Fuel Rail: Service and Repair

Fig. 5 Fuel supply and return lines:

Fig. 6 Fuel rail & fuel regulator attaching bolt locations:

REMOVAL
CAUTION: The fuel system on remains pressurized after engine has been turned OFF. Release pressure prior to opening system. Service and Repair
1. Disconnect battery ground cable.
2. Remove fuel tank cap to relieve fuel tank pressure, then install cap.
3. Place shop towels under fuel lines to absorb spilled fuel, then using tool No. 6182 or equivalent, disconnect gray return line (A) from pressure regulator (B) and black supply line (C) from fuel rail (D).
4. Mark fuel injector electrical connectors with correlating fuel injector number, disconnect injector wire harness and set off to one side, then disconnect accelerator cable from throttle body and holding bracket.
5. Disconnect cruise control cable at throttle lever, if equipped. Remove cruise control cable connector by hand. If connector is damaged, complete cruise control servo and cable assembly must be replaced.
6. Remove fuel rail attaching bolts (E), then the fuel pressure regulator attaching bolts (F),
7. Pull fuel rails, regulator and injector assembly up and out of intake manifold ports, then out from under transmission kick-down cable and remove from vehicle.

INSTALLATION
1. Lubricate the injector O-rings with a thin film of clean engine oil and position the fuel rail assembly with the injectors above the holes in the intake manifold.
2. Being careful not to damage the O-rings, push the injectors into their respective holes.
3. Install and tighten the hold down bolts for the fuel rail and the fuel regulator.
4. Connect the cruise control and accelerator cables.
5. Connect the injector wire harness.
6. Connect the fuel supply tube and the fuel return tube.
7. Connect the vacuum hose to the fuel pressure regulator.
8. Connect the negative battery cable.
9. On early model vehicles turn the key to the ON position to pressurize the system and check for leaks. On late model vehicles, use the DRB II to select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks.
CAUTION:Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test.