Fuel Rail: Service and Repair

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE TURNED OFF). BEFORE SERVICING FUEL RAIL ASSEMBLY, FUEL SYSTEM PRESSURE MUST BE RELEASED.

To release fuel pressure, refer to Fuel System Pressure Release Procedure.

Fuel Rail Assembly:

CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connecting hose. Due to the design of this connecting hose, it does not use any clamps. Never attempt to install a clamping device of any kind to hose. When removing fuel rail assembly for any reason, be careful not to bend or kink connecting hose.

REMOVAL
1. Remove negative battery cable at battery.
2. Remove air cleaner.
3. Perform fuel pressure release procedure.
4. Remove throttle body from intake manifold. Refer to Throttle Body removal.

A/C Compressor Support Bracket - Typical:

5. If equipped with air conditioning, remove A-shaped A/C compressor-to-intake manifold support bracket (three bolts).

Fuel Injector Connectors - Typical:

6. Disconnect electrical connectors at all fuel injectors. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification.
7. Disconnect fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures,
8. Remove remaining fuel rail mounting bolts.
9. Clean dirt/debris from each fuel injector at intake manifold.
10. Gently rock and pull left fuel rail until fuel injectors just start to clear intake manifold. Gently rock and pull right fuel rail until fuel injectors just start to clear intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared intake manifold.
11. Remove fuel rail (with injectors attached) from engine.

Fuel Injector Mounting - Typical:

Injector Retaining Clips - Typical Injector:

12. Remove clip(s) retaining injector(s) to fuel rail.

INSTALLATION
1. Apply a small amount of clean engine oil to each fuel injector O-ring. This will help in fuel rail installation,
2. Install injector(s) and injector clip(s) to fuel rail,
3. Position fuel rail/fuel injector assembly to injector openings on intake manifold.
4. Guide each injector into intake manifold. Be careful not to tear injector O-ring.
5. Push right fuel rail down until fuel injectors have bottomed on injector shoulder. Push left fuel rail down until fuel injectors have bottomed on injector shoulder.
6. Install fuel rail mounting bolts.
7. Connect electrical connector to intake manifold air temperature sensor.
8. Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged.
9. Install A/C support bracket (if equipped).
10. Install throttle body to intake manifold. Refer to Throttle Body installation.
11. Install fuel tube (line) at side of fuel rail. Refer to Quick-Connect Fittings for procedures.
12. Install air cleaner.
13. Connect battery cable to battery.
14. Start engine and check for leaks.