Fuel Rail - Removal

REMOVAL - 4.0L





WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.

1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure. Service and Repair
3. Remove negative battery cable at battery.
4. Disconnect air duct at throttle body.
5. Remove air intake ducts between throttle body and air filter assembly.
6. Remove upper half of intake manifold.
7. Disconnect electrical connectors (3) at all six fuel injectors. For procedures, proceed to step 10.
8. Disconnect fuel line latch clip and fuel line (1) at fuel rail. A special tool will be necessary for fuel line disconnection. Refer to Quick Connect Fittings for removal procedures.
9. Remove necessary vacuum/vapor lines at throttle body.




10. 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 throttle body sensors.




12. Remove four fuel rail mounting bolts (2).
13. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
14. Remove fuel rail (with injectors attached) from engine.
15. If fuel injectors are to be removed, refer to Fuel Injector Removal.