Fuel Rail: Service and Repair

FUEL RAIL







Exploded View

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.

1. Relieve the fuel pressure.
2. Disconnect the battery ground cable.
3. Remove the engine cover.
4. Remove the air cleaner and the air cleaner outlet tube.
5. Disconnect the fuel tube spring lock coupling.







6. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor hoses.
7. Remove the exhaust manifold-to-EGR valve tube.
- To install, tighten to 50 Nm (37 lb-ft).







8. Remove the retaining nut for the transmission fluid level indicator and tube.
- To install, tighten to 28 Nm (21 lb-ft).







9. Remove the retaining bolt and position the transmission fluid level indicator and tube aside.
- To install, tighten to 10 Nm (89 lb-in).

10. Disconnect the fuel rail pressure and temperature sensor vacuum hose and the electrical connector.
11. Remove the positive crankcase ventilation (PCV) hose from the back of the intake manifold and the RH valve cover.
12. Disconnect the 8 fuel injector electrical connectors.







13. Disconnect the evaporative emission (EVAP) canister purge valve hose.
14. Remove the 4 fuel rail bolts.
- To install, tighten to 10 Nm (89 lb-in).

15. Remove the fuel rail and the fuel injectors as an assembly.







16. Remove the 8 fuel injectors from the fuel rail.







17. Remove and discard the O-ring seals from each fuel injector.
- Lubricate the new fuel injector O-ring seals with clean motor oil.

18. CAUTION: Check for fuel leakage after installation is complete.

NOTE: Be sure the 8 fuel injectors and the fuel rail are fully seated.

To install, reverse the removal procedure.