Fuel Rail: Service and Repair

REMOVAL PROCEDURE

TOOLS REQUIRED
J 34730 Fuel Pressure Gauge





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 the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure. Service and Repair




2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed (2) and return (1) pipes from the fuel rail.




4. Remove the vacuum hose from the fuel pressure regulator.




5. Remove the vacuum hose from the throttle body.




6. Remove the spark plug wires from the ignition coils.




7. Remove the fuel injector electrical connectors from the fuel injectors.




8. Remove the fuel rail hold-down bolts.
9. Remove the fuel rail with equal force on both sides of the fuel rail.

INSTALLATION PROCEDURE

Fuel Rail:

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-ring in the proper position. It the upper and lower O-ring 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-ring are the same size but are made of different materials.

NOTE:
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors the fuel injector tips, the injector O-ring. 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. The O-ring must be replaced on all components that are replaced.
2. Lightly oil the fuel injector (4) O-ring with clean motor oil.




3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Install the fuel rail hold down bolts.

Tighten
Tighten the fuel rail hold-down bolts to 10 N.m (7 lb ft).




6. Install the fuel injector electrical connectors to the fuel injectors.




7. Install the fuel feed (2) and return (1) pipes to the fuel rail.




8. Install the vacuum hose to the fuel pressure regulator.




9. Install the vacuum hose to the throttle body.




10. Install the spark plug wires to the ignition coils.




11. Reconnect the negative battery cable.
11.1. Turn the ignition switch On for 2 seconds.
11.2. Turn the ignition switch Off for 10 seconds.
11.3. Turn the ignition switch On.
11.4. Check for leaks.
12. Install the fuel injector sight shield.