Fuel Rail: Service and Repair

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.




1. Release the fuel system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the throttle body inlet hose (3) and remove from throttle body.
4. Disconnect the purge hose from the throttle body (1).
5. Unlock and disconnect the electrical connection at the throttle body (2).




6. Remove the throttle control shield.




7. Remove the throttle and speed control cables from the throttle body.
8. Remove the cables from the throttle body bracket.
9. Unlock and disconnect the MAP sensor electrical connector.




10. Remove the vacuum lines from the rear of the intake manifold.




11. Remove the 5 bolts from the front of the intake manifold.
12. Remove the 2 bolts from the rear of the intake manifold.
13. Remove the intake manifold. Cover the lower intake manifold openings.




14. Drain the Coolant system,
15. Remove the upper radiator hose clamp.




16. Remove the 2 small hoses from the thermostat housing.




17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.




18. Rotate upper radiator hose up and out of the way.

NOTE: Wrap shop towels around hose to catch any gasoline spillage.




19. Disconnect the fuel line from the fuel rail. Refer to the Quick-Connect Fittings.




20. Unlock and disconnect the electrical connectors from the fuel injectors.
21. Remove the wiring harness from the fuel rail.
22. Remove the 2 bolts from the fuel rail.




23. Remove the fuel rail and injectors from the intake manifold.

INSTALLATION




1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Install injector into cup of fuel rail.
4. Install retaining clip and check to ensure injector is properly captured.




5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
6. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 22.5 ± 3 N.m (200 ± 30 in. lbs.).




7. Install the wiring harness to the fuel rail.
8. Connect and lock the electrical connectors to the fuel injectors.
9. Connect the fuel line to the fuel rail. Refer to Quick Connect Fittings.




10. Rotate the assembly back into place.




11. Install the 2 bolts to the thermostat housing tighten to 12.5 N.m (110 in. lbs.).




12. Move the upper radiator house clamp back into place.




13. Install the 2 small hoses to the thermostat housing.
14. Fill the Coolant system.




15. Install the intake manifold.
16. Install the 2 bolts to the rear of the intake manifold tighten to 28 N.m (250 in. lbs.).
17. Install the 5 bolts to the front of the intake manifold and tighten to 28 N.m (250 in. lbs.).




18. Install the vacuum lines to the rear of the intake manifold.




19. Connect and lock the MAP sensor electrical connector.




20. Install the cables to the throttle body bracket.
21. Install the throttle and speed control cables to the throttle body.
22. Install the throttle control shield.




23. Connect and lock the electrical connections at the throttle body.
24. Connect the purge hose to the throttle body.
25. Connect the throttle body inlet hose to the throttle body and tighten clamps to 3 N.m ±1 (25 in. lbs ± 5) torque.
26. Connect the negative battery cable.
27. Use the San Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.