Fuel Rail: Service and Repair

REMOVAL






1. Disconnect the battery ground cable.

NOTE: When battery voltage is removed from the Powertrain Control Module (PCM), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveablilty and performance.

NOTE: Before performing fuel pressure procedures, make sure the ignition switch is in the OFF position.






2. Remove the fuel pressure relief valve cap and attach fuel pressure gauge T80L-9974-B.






3. Open the manual valve on fuel pressure gauge T80L-9974-B slowly to relieve the fuel system pressure.






4. Disconnect the Crankshaft Position (CKP) sensor electrical connector.






5. Disconnect the two main engine harness electrical connectors above the RH front wheel well.






6. Disconnect the four fuel injector electrical connectors.






7. Disconnect the Camshaft Position (CMP) sensor electrical connector.






8. Grasp the plastic wiring harness routing rail and pull upward separating it from the fuel injection supply manifold. Position the harness aside.






9. Disconnect the vacuum line from the top of the fuel pressure regulator and position it aside.






10. Use disconnect tool D87L-9280-B to disconnect the fuel inlet line to the fuel injection supply manifold.
11. Unclip fuel inlet line from the fuel line support bracket.






12. Use disconnect tool D87L-9280-A to disconnect the fuel return line from the fuel injection supply manifold.






13. Remove the fuel injection supply manifold bolts.

CAUTION: The fuel injection supply manifold and the fuel injectors must be handled with extreme care to prevent damage to the sealing areas and sensitive fuel metering orifices.

14. Carefully disengage the fuel injection supply manifold from the fuel injectors and remove the manifold.

INSTALLATION

NOTE: Lubricate fuel injector O-ring seals with 5W30 engine oil prior to installing the fuel injection supply manifold.

1. Position the fuel injection supply manifold on top of the fuel injectors and push down to ensure all fuel injector O-ring seals are seated in the fuel injection supply manifold cups and the Intake Manifold Runner Control (IMRC) assembly.






2. Install the fuel injection supply manifold bolts.
3. Connect the fuel return line to the fuel injection supply manifold.
4. Connect the fuel inlet line to the fuel injection supply manifold.
5. Clip the fuel supply line into the fuel line support bracket.






6. Install the vacuum line on the top of the fuel pressure regulator.






7. Position the wiring harness into place. Grasp plastic wiring harness routing rail and slide it back onto the fuel injection supply manifold.






8. Connect the CMP sensor electrical connector.






9. Connect the fuel injector electrical connectors.






10. Connect the two main harness electrical connectors.





11. Connect the CKP sensor electrical connector.
12. Connect the battery ground cable.
13. Start the engine and let it run for two minutes. Turn the engine off and inspect it for fuel leaks.