Fuel Rail: Service and Repair

Fuel Rail Assembly:

REMOVE OR DISCONNECT

CAUTION:
^ Care must be taken not to damage/dirty the fuel injector electrical connectors, the fuel injector tips, the O-Rings, and the inlet and the outlet of the fuel rail.
^ Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components.
^ The fuel rail assembly must not be immersed in solvent in order to prevent damage to the fuel rail assembly.

1. Bleed the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure
2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed and return pipes from the fuel rail tubes by squeezing tabs and pulling the lines apart.
4. Remove the vacuum line from the pressure regulator.
5. Remove the vacuum lines from the throttle body.
6. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
7. Remove the generator and rear generator mounting bracket.
8. Remove the injector electrical connectors.
9. Remove the injector electrical harness clips holding harness to front of fuel rail.
10. Remove the fuel rail hold-down bolts.

CAUTION: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

Remove the fuel rail with equal force on both sides of the fuel rail.


INSTALL OR CONNECT

WARNING: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-Rings in the proper position. If the upper and lower O-Rings are different colors (black and brown), be sure to install the black O-Ring in the upper position and the brown O-Ring in the lower position on the fuel injector. The O-Rings are the same size but are made of different materials.

1. The O-Rings must be replaced on all components that are replaced.
2. Lightly oil the fuel injector O-Rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

5. Install the fuel rail hold-down bolts.
- Torque the fuel rail hold-down bolts to 10 Nm (7 lb. ft.).
6. Install the generator and rear generator mounting bracket.
7. Install the injector electrical harness clips holding harness to front of fuel rail.
8. Install the injector electrical connectors.
9. Install the ignition coil wires to coil and retainer clips on top of super charger.
10. Install the vacuum line to the pressure regulator.
11. Install the vacuum lines to throttle.
12. Install the fuel feed and return pipes to the fuel rail tubes by squeezing tabs and pulling the lines apart.