Fuel Rail: Service and Repair

Fuel Rail Storm:

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Relieve fuel pressure. Refer to Fuel Pressure Release.
3. Air cleaner duct assembly.
4. Throttle cable at throttle body and bracket.
5. Electrical connectors from:
a. TP sensor.
b. IAC valve.
c. IAT sensor.

6. Vacuum and coolant hoses from throttle body.
7. Throttle body.
8. Vacuum and PCV hoses from plenum.
9. ECM ground wires.
10. Engine lift hook and plenum support brackets.
11. Plenum assembly.
12. Injector electrical connectors.

CAUTION: Use a back-up wrench when removing fuel lines or damage to fuel rail or internal O-rings will occur.

13. Fuel pressure line at fuel rail.
14. Fuel return line at pressure regulator.
15. Fuel rail assembly.

NOTE: If an injector becomes separated from the rail and remains in the cylinder head, both injector O-ring seals and the retainer clip must be replaced.

INSTALL OR CONNECT
1. If separated from fuel rail, install injector(s) into fuel rail injector socket(s).
2. Injector retainer clip on injector assembly. Clip should be parallel to injector electrical connector.
3. Fuel injector assemblies into fuel rail injector sockets, with electrical connectors and clips facing outward. Line up injectors with injector sockets, push upward slowly to engage retainer clips on fuel rail ledge then push injectors all the way in to firmly seat them in the sockets.

CAUTION: Use a back-up wrench when tightening fuel lines or damage to fuel rail or internal O-rings will occur.

4. Fuel pressure and return lines. Install and tighten return tube retainer screw.
5. Fuel rail assembly into cylinder head and tighten attaching bolts to 3.2 Nm (28 lbs in).
6. Injector electrical connectors. Rotate injector(s) as required to avoid stretching wire harness.
7. Plenum assembly.
8. Plenum support and engine lift hook brackets.
9. ECM ground wires.
10. Vacuum and PCV hoses to plenum.
11. Throttle body with new gasket and tighten bolts to 22 Nm (16 lb ft).
12. Coolant and vacuum hoses to throttle body.
13. Electrical connectors to:
a. TP sensor.
b. IAC valve.
c. IAT sensor.

14. Throttle cable to throttle body and bracket.
15. Air cleaner duct assembly.
16. Negative battery cable.
17. Turn ignition switch to "ON" and then back to "LOCK" to pressurize the fuel system. Check for any fuel leaks.