Fuel Rail: Service and Repair

FUEL RAIL- 2.3L REMOVAL/INSTALLATION

Removal

WARNING:
- Do not smoke or carry lighted tobacco or 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.
- 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. Failure to follow these instructions may result in serious personal injury.

Fuel Rail And Fuel Injector-2.3L Exploded View:

1. Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE.
2. Disconnect the negative battery cable. See BATTERY DISCONNECT.
3. Disconnect the fuel supply tube quick connect coupling at the fuel rail. See QUICK RELEASE COUPLING - DOUBLE LOCKING.
4. Disconnect the fuel rail pressure and temperature vacuum tube and electrical connector.
5. Disconnect the 4 fuel injector electrical connectors.
6. Remove the nut and position the radio capacitor aside.
7. Detach the wire harness retainer from the valve cover stud bolt.
8. Detach the 2 pin-type wire harness retainers from the fuel rail.
9. Remove the 2 fuel rail stud bolts.
10. Remove the fuel rail and injectors as an assembly.
11. Remove the 4 fuel injector retainer clips and the 4 fuel injectors.
- Remove and discard the 8 fuel injector O-ring seals.

Installation
1. Install the 4 fuel injector clips and the 4 fuel injectors.

CAUTION: Use O-ring seals that are made of fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-rings seals.

NOTE: Do not reuse the O-ring seals.

2. Install the fuel rail and injectors as an assembly.
3. Install the 2 fuel rail bolts.
- Tighten to 23 N.m {2.3 kgf.m, 17 ft.lbf}.

4. Attach the 2 pin-type wire harness retainers to the fuel rail.
5. Attach the wire harness retainer to the valve cover stud bolt.
6. Position the radio capacitor and install the nut.
- Tighten to 10 N.m {1.0 kgf.m, 89 in.lbf}.

7. Connect the 4 fuel injector electrical connectors.
8. Connect the fuel rail pressure and temperature sensor vacuum tube and electrical connector.
9. Connect the fuel supply tube quick connect at the fuel rail. See QUICK RELEASE COUPLING - DOUBLE LOCKING.
10. Connect the battery ground cable. See BATTERY DISCONNECT.