Fuel Rail: Service and Repair

REMOVAL

1. Disconnect battery ground cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy.

2. Remove fuel tank filler cap and release pressure.

3. Release pressure from fuel system, refer to Service and Repair / Fuel Pressure Relief Procedure.

4. Remove supercharger, refer to Supercharger / Service and Repair. Supercharger Assembly

5. Using Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 inch), D87L-9280-B (1/2 inch) or equivalent, disconnect the inlet and outlet fuel lines from the fuel injection supply manifold.

6. Remove four fuel rail assembly retaining bolts (two on each side).

7. Remove fuel pressure regulator bracket retaining bolt.

NOTE: It may be easier to remove fuel injectors with the fuel injection supply manifold as an assembly.

8. Carefully disengage fuel injection supply manifold from fuel injectors and remove fuel injection supply manifold.

9. Use a rocking. side-to-side motion while lifting to remove fuel injectors from cylinder head pockets.

INSTALLATION

Fuel Injection Supply Manifold:

NOTE: When installing fuel injection supply manifold with new or used fuel injectors, particular attention should be paid to proper 0-rings seating to ensure that no fuel leaks exist.

1. Make sure injector caps are clean and free of contamination.

2. Place the fuel injector supply manifold assembly over each of the injectors and seat injectors into fuel rail. Ensure injectors are well seated into the fuel injector supply manifold assembly.

3. Secure the fuel injector supply manifold assembly using four retaining bolts. Tighten to 8-11 Nm (71-97 lb in).

4. Install fuel pressure regulator bracket retaining bolt. Tighten to 20-30 Nm (15-22 lb ft).

5. Install supercharger assembly.

6. Install fuel inlet and outlet fuel lines spring lock couplings.

7. Firmly push and pull the fuel inlet and outlet lines to ensure that they are positively locked to the fuel rail connectors.