Fuel Rail: Service and Repair

Fuel Rail Assembly Identification:

Fuel Rail Removal:

Fuel Rail Assembly:

FUEL RAIL REMOVAL AND REPLACEMENT PROCEDURE

TOOLS REQUIRED
J 41081 Injector Remover
J 37088-A, tool set, Fuel Line Quick-Connect Separator

NOTICE:
^ Use care in removing the fuel rail assembly to prevent damage to the injector electrical connector terminals and the injector spray tips. When removed, support the rail to avoid damaging its components.
^ Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped, and holes plugged, during servicing.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Intake manifold top cover.
3. Relieve fuel system pressure. Refer to Fuel System Pressure Relief Procedure.
4. Intake Air Temperature (IAT) sensor connector.
5. Crankcase vent pipe at air intake duct.
6. Air intake duct with air cleaner housing.
7. EGR pipe at throttle body spacer.
8. Brake booster vacuum hose at intake manifold vacuum fitting.
9. Front bank spark plug wires and lay aside.
10. Injector electrical connectors and Manifold Absolute Pressure (MAP) sensor electrical connector. Lay harness aside.
11. Transaxle vent hose and vacuum lines from Idle Speed Control (ISC) actuator bracket.
12. Vacuum manifold at throttle body.
13. Fuel rail ground wire at rear cylinder head.
14. Fuel pressure regulator vacuum line.
15. Quick-connect fittings at fuel rail:
a. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within fitting.

CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Using compressed air, blow dirt out of fitting.
c. Choose correct tool from J 37088-A tool set for size of fining. Insert tool into female connector, then push/pull inward to release locking tabs.
d. Pull connection apart.

CLEAN AND INSPECT
^ Using a clean shop towel, wipe off male pipe end.
^ Inspect both ends of fining for dirt and burrs. Clean or replace components/assemblies as required.

NOTICE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to O-ring sealing surface.

16. Fuel rail bracket at EGR valve.
17. Throttle body mount bolts.
18. Throttle body spacer.
19. Release locking tabs on fuel rail and pry each injector out of intake manifold using J 41081.
20. Fuel rail assembly.

DISASSEMBLE
1. Injectors from fuel rail.
2. Upper and lower O-rings from injectors. Discard O-rings.

CLEAN
Throttle body O-ring sealing surfaces.

ASSEMBLE
1. Lubricate new upper and lower injector Orings with clean engine oil and install on injectors.
2. Injectors to fuel rail with new retainer clips.

INSTALL OR CONNECT
1. Fuel rail with injectors to intake manifold.
2. Throttle body spacer, new throttle body Oring seal, throttle body, and throttle body mount bolts. Tighten Throttle body mount bolts to 12 Nm (106 lb. in.).
3. Quick-connect fittings to fuel rail:
a. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
b. Push both sides of fining together to cause the retaining tabs/fingers to snap into place.
c. Once installed, pull on both sides of fitting to make sure connection is secure.
4. Fuel rail bracket at EGR valve.
5. Fuel pressure regulator vacuum line.
6. Fuel rail ground wire at rear cylinder head.
7. Vacuum manifold at throttle body.
8. Transaxle vent hose and vacuum lines to ISC actuator bracket.
9. Injector electrical connectors and MAP sensor electrical connector.
10. Front bank spark plug wires.
11. Brake booster vacuum hose at intake manifold vacuum fitting.
12. EGR pipe at throttle body spacer. Tighten EGR pipe bolt to 28 Nm (21 lb. ft.).
13. Air intake duct with air cleaner housing.
14. Crankcase vent pipe at air intake duct.
15. IAT sensor connector.
16. Tighten fuel filler cap.
17. Negative battery cable.

INSPECT
Turn ignition switch to the 'ON' position for two seconds, then turn to the 'OFF' position for ten seconds. Again turn to the 'ON' position and check for fuel leaks.

18. Intake manifold top cover. Tighten Intake manifold top cover nuts to 2 Nm (18 lb. in.).