Fuel Rail: Service and Repair

REMOVAL

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

1. Remove negative battery cable at battery.
2. Remove air cleaner housing and tube.
3. Perform fuel pressure release procedure. Refer to Fuel Delivery System.
4. Disconnect throttle body linkage and remove throttle body from intake manifold.

Fig. 39 Ignition Coil Pack And Mounting Bracket:

5. Remove ignition coil pack and bracket assembly (Fig. 39) at intake manifold and right engine valve cover (four bolts).
6. Remove upper half of intake manifold. Refer to Engines for procedures.

Fig. 40 Remove/Install Fuel Injector Connector:

7. Disconnect electrical connectors at all fuel injectors. To remove connector refer to (Fig. 40). Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification.
8. Disconnect fuel line quick-connect fitting at left-rear end of fuel rail. A special 3/8 inch fuel line disconnection tool will be necessary.

Fig. 41 Fuel Rail Mounting Bolts (Typical):

9. Remove the six fuel rail mounting bolts from the lower half of intake manifold (Fig. 41).
10. Gently rock and pull the left fuel rail until the fuel injectors just start to clear the intake manifold. Gently rock and pull the right fuel rail until the fuel injectors just start to clear the intake manifold. Repeat this procedure (left/right) until all fuel injectors have cleared the intake manifold.
11. Remove fuel rail (with injectors attached) from engine.

Fig. 37 Fuel Injector Mounting (Typical):

Fig. 38 Injector Retaining Clips (Typical):

12. Remove the clip(s) retaining the injector(s) to fuel rail (Fig. 37) or (Fig. 38).

INSTALLATION
1. Apply a small amount of 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.

NOTE: The fuel injector electrical connectors on all 10 injectors should be facing to the right (passenger) side of the vehicle (Fig. 41).

4. Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold.
5. Guide each injector into the intake manifold. Be careful not to tear the injector O-ring.
6. Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder.
7. Install the six fuel rail mounting bolts into the lower half of intake manifold. Tighten bolts to 15 Nm (136 in. lbs.) torque.
8. Connect electrical connectors at all fuel injectors.To remove connector refer to (Fig. 40). Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. The injector wiring harness is numerically tagged.
9. Install upper half of intake manifold. Refer to Engines for procedures.
10. Connect main fuel line at fuel rail. Refer to Quick-Connect Fittings for procedures.
11. Install ignition coil pack and bracket assembly at intake manifold and right engine valve cover (four bolts).
12. Install throttle body to intake manifold.
13. Install throttle body linkage to throttle body.
14. Install air cleaner tube and housing.
15. Install negative battery cable at battery.
16. Start engine and check for leaks.