Fuel Rail: Service and Repair

Fuel Rail

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

1. Release the fuel system pressure.

2. Disconnect the battery ground cable.

3. Remove the intake manifold.

4.

5. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the fuel injection pump flare nut.

NOTE: Make sure that a new high pressure fuel tube is installed.

7. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.

NOTE: Make sure that new fuel rail bolts are installed.

8. Remove any of the fuel injectors that remained in the fuel rail.

9. NOTE: Make sure that new fuel injector retainer clips are installed.

10. Using the Slide Hammer and the Fuel Injector Remover, remove the fuel injectors.
1. 307-005 (T59L-100-B) or equivalent.

2. 310-206.

11. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

NOTE: Do not use compressed air to clean the tip of the fuel injector.

NOTE: Do not use a brush to clean the tip of the fuel injector.

1. 310-205.

Installation

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.

1. NOTE: Discard the upper fuel injector O-ring seals and the upper fuel injector O-ring seal support rings.

2. NOTICE: Do not attempt to cut the lower Teflon(R) seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon(R) seals, not to scratch, nick or gouge the fuel injectors.
Pull the lower Teflon(R) seal away from the injector with narrow tip pliers.

3. Carefully cut and discard the lower fuel injector Teflon(R) seals.

4. Place the Teflon(R) Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal recess is exposed.
1. 303-1567.

2. 310-207.

3. NOTE: Make sure that new lower fuel injector Teflon(R) seals are installed.

4. 310-207.

5. NOTE: Make sure the Teflon(R) seal is fully seated in the groove on the fuel injector before sizing the seal.

NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon(R) seal expansion.

1. 303-1567.

6. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.

NOTE: Lubricate the upper fuel injector O-ring seals with clean engine oil.

NOTE: Make sure that new upper fuel injector O-ring seals, upper fuel injector O-ring seal support rings and fuel injector retainer clips are installed.

7. NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.

NOTE: The fuel rail pressure sensor must be replaced if it is removed from the fuel rail.

8. NOTE: Do not lubricate the new lower Teflon(R) fuel injector seals.

NOTE: Make sure that new fuel rail bolts are installed.

NOTE: Push down on the fuel rail face above the injectors.

Tighten the 5 fuel rail bolts in the following 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.

- Stage 2: Tighten an additional 26 degrees in the sequence shown.

10. NOTE: Make sure that a new high pressure fuel tube is installed.

- Hand tighten the high pressure fuel tube-to-fuel rail flare nut.

- Hand tighten the high pressure fuel tube-to-fuel injection pump flare nut.

11. Loosely install the 2 high pressure fuel tube bracket bolts.

12. Tighten the 2 high pressure fuel tube flare nuts in the following 2 stages.

NOTE: Calculate the correct torque wrench setting for the following torque.

- Stage 1: Using a torque adapter, tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten an additional 30 degrees.

13. Tighten to 10 Nm (89 lb-in).

14. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will aid in installing the fuel injection pump noise insulator and reduce the risk of damage.

15. Install the intake manifold.

16. Connect the battery ground cable.

17. Pressurize the fuel system,