Fuel Rail: Service and Repair

Removal Procedure

CAUTION: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.




1. Relieve the fuel system pressure.
Fuel Pressure Release

2. Disconnect the negative battery cable.
3. Remove the spark plug cover.
4. Disconnect the fuel injector harness connectors.
5. Remove the fuel line at the fuel pressure regulator.
Fuel Pressure Regulator




6. Remove the fuel inlet line.
7. Remove the fuel rail mounting bolts.

NOTE: Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dint and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service.

Important: If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.

8. Remove the fuel rail with the fuel injectors attached.




9. Remove the fuel injector retainer clips.
10. Remove the fuel injectors by pulling down and out.
11. Discard the fuel injector O-rings.

Installation Procedure

Important: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.




1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
3. Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge.
4. Make sure that the clip is parallel to the fuel injector harness connector.




5. Install the fuel rail assembly into the cylinder head.

6. Install the fuel rail mounting bolts.
Tighten
Tighten the fuel rail mounting bolts to 18 lb.ft (25 N.m).

7. Connect the fuel inlet hose.
8. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wire harness.
9. Install the fuel pressure regulator.
10. Install the spark plug cover.
11. Connect the negative battery cable.
12. Perform a leak check of the fuel rail and fuel injectors.