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 tubes. Due to design of tubes, it does not use any clamps. Never attempt to install a clamping device of any kind to tubes. When removing fuel rail assembly for any reason, be careful not to bend or kink tubes.




1. Remove fuel tank filler tube cap.
2. Perform Fuel System Pressure Release Procedure.
3. Remove negative battery cable at battery.
4. Remove air duct at throttle body air box.
5. Remove air box at throttle body.
6. Remove air resonator mounting bracket at front of throttle body (2 bolts).
7. Disconnect fuel line latch clip and fuel line at fuel rail. A tool will be necessary for fuel line disconnection.
8. Remove necessary vacuum lines at throttle body.
9. Disconnect electrical connectors at all 6 fuel injectors. 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.
10. Disconnect electrical connectors at all throttle body sensors.
11. Remove 6 ignition coils.




12. Remove four fuel rail mounting bolts (1).
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. Fuel injectors are to be removed.

INSTALLATION




1. Fuel injectors are to be installed.
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 cylinder head.
5. Guide each injector into cylinder head. Be careful not to tear injector O-rings.
6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.
7. Install 4 fuel rail mounting bolts and tighten.
8. Install 6 ignition coils.
9. Connect electrical connectors to throttle body.




10. Connect electrical connectors at all fuel injectors. 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.
11. Connect necessary vacuum lines to throttle body.
12. Install air resonator mounting bracket near front of throttle body (2 bolts).
13. Connect fuel line latch clip and fuel line to fuel rail.
14. Install air box to throttle body.
15. Install air duct to air box.
16. Connect battery cable to battery.
17. Start engine and check for leaks.