Fuel Rail: Service and Repair

REMOVAL

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

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




1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
3. Remove negative battery cable at battery.
4. Remove flex tube (air cleaner housing to engine).
5. Remove air resonator box at throttle body.
6. Disconnect all spark plug cables from all spark plugs and ignition coils. Do not remove cables from cable routing tray. Note original cable positions while removing.




7. Remove spark plug cable tray from engine by releasing 4 retaining clips (2). Remove tray and cables from engine as an assembly.
8. Disconnect electrical connectors at all 8 ignition coils. Refer to Ignition Coil Removal/Installation.
9. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick-Connect Fittings.




10. Disconnect electrical connectors at all 8 fuel injectors. Refer to graphic.. 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. If harness is not tagged, note wiring location before removal.




11. Disconnect electrical connectors at all throttle body sensors.
12. Remove four fuel rail mounting bolts (2) and holddown clamps.
13. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes. Repeat this procedure (left/right) until all injectors have cleared machined holes.
14. Remove fuel rail (with injectors attached) from engine.

INSTALLATION
1. If fuel injectors are to be installed, refer to Fuel Injector Removal/Installation.
2. Clean out fuel injector machined bores in intake manifold.
3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold.
5. Guide each injector into intake manifold. Be careful not to tear injector O-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down until injectors have bottomed on shoulders.
7. Install 4 fuel rail holddown clamps and 4 mounting bolts to 11 N.m (100 in. lbs)
8. Position spark plug cable tray and cable assembly to intake manifold. Snap 4 cable tray retaining clips into intake manifold.
9. Install all cables to spark plugs and ignition coils.
10. Connect electrical connector to throttle body.
11. Install electrical connectors to all 8 ignition coils. Refer to Ignition Coil Removal/Installation.
12. Connect electrical connector to throttle body.
13. Connect electrical connectors at all fuel injectors. Refer to graphic. 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.
14. Connect fuel line latch clip and fuel line to fuel rail. Refer to Quick-Connect Fittings.
15. Install air resonator to throttle body (2 bolts).
16. Install flexible air duct to air box.
17. Connect battery cable to battery.
18. Start engine and check for leaks.