Fuel Rail: Service and Repair

FUEL RAIL TRANSFER LINE REPLACEMENT

TOOLS REQUIRED
^ J 37088 Fuel Line Disconnect Set
^ J 44095 Fuel Pressure Adapter Fitting
^ SA9127E Gauge Bar Set

REMOVAL

CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANYTIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.




1. Disconnect negative battery cable.

2. Loosen clamp at air cleaner assembly and throttle body assembly.
3. Remove attachment bolts from outlet resonator/duct assembly to support bracket.
4. Remove outlet resonator/duct assembly.




5. Remove resonator outlet duct assembly bracket from manifold.

CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.




6. Relieve fuel system pressure. Refer to "Fuel System Pressure Relief" procedure in the Fuel System.
7. Disconnect Gauge Bar Set SA9127E (or equivalent) and Fuel Pressure Adapter Fitting J 44095 (or equivalent) after pressure has been relieved.
8. Disconnect fuel transfer line at quick connect from fuel line using Fuel Line Disconnect Set J 37088 (or equivalent) (blue tool).




9. Remove fuel line bracket bolt to manifold at rear of intake manifold.




10. Lift and support intake manifold. Refer to "Intake Manifold Lift and Support" procedure in the Induction System.




11. While supporting the fuel rail assembly with an open-end wrench, loosen transfer line fitting at fuel rail.
12. Remove fuel line bracket bolt to manifold.




13. Remove fuel transfer line.

INSTALLATION




1. Install fuel transfer line into position.

NOTE: To avoid damaging fuel rail assemblies, support fuel rail fittings with open-end wrench during installation.

2. Hand tighten both fuel transfer line fittings to fuel rails.

Torque:
Fuel Transfer Line Fittings-to-Fuel Rail - L81: 15 N.m (11 ft-lbs)

3. Install fuel line bracket to manifold

Torque:
Fuel Line Bracket-to-Manifold Bolt: 6 N.m (47 in-lbs)

4. Install intake manifold.




5. Install fuel transfer line bracket bolt intake manifold.

Torque:
Fuel Transfer Line Bracket Bolt-to-Intake - L81: 4.4 N.m (39 in-lbs)




6. Install outlet resonator/duct assembly bracket to manifold.
7. Install outlet resonator/duct assembly bracket nuts.

Torque:
Outlet Resonator/Duct Assembly Bracket-to-Intake Manifold Nuts - L81: 5 N.m (44 in-lbs)

IMPORTANT: An audible click noise can be heard when fuel line is installed. Slightly pull rearward on line to assure connection is fully seated.

8. Connect fuel line to fuel transfer line.




9. Install outlet resonator/duct assembly into position.
10. Tighten clamp at throttle body assembly.
11. Position outlet resonator/duct assembly to support bracket and install bolts.

Torque:
Outlet Resonator/Duct Assembly-to-Support Bracket Bolts - L81: 10 N.m (89 in-lbs)

12. Tighten clamp at air cleaner assembly.
13. Connect negative battery cable.

Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)