Fuel Rail: Service and Repair
Tools RequiredInjector Remover J 41081
Fuel Line Quick-Connect Separator J37088
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 pipes and passages. Fittings should be capped, and holes plugged, during servicing.
Removal Procedure
1. Remove the negative battery cable.
Intake Manifold Top Cover:
2. Remove the intake manifold top cover.
3. Relieve the fuel system pressure. Refer to Fuel Pressure Release.
4. Remove the intake air duct.
5. Remove the MAP sensor electrical connector.
6. Remove the EGR pipe and crankcase ventilation pipe at throttle body spacer.
7. Remove the brake booster vacuum hose at intake manifold.
8. Remove the front bank spark plug wires.
9. Remove the injector harness electrical connectors.
10. Remove transaxle vent hose from clip.
Fuel Pressure Regulator:
11. Remove the fuel pressure regulator vacuum line.
12. Disconnect the quick-connect fittings at fuel rail.
13. Grasp both sides of fitting.
Fuel Rail:
14. Remove the fuel rail ground wire at rear cylinder head.
15. Twist the female connector 1/4 turn in each direction to loosen any dirt within fitting.
Caution: Wear safety glasses when using compressed air because flying dirt particles may cause eye injury.
16. Blow dirt out of fitting using compressed air.
17. Choose correct tool from J 37088 tool set for size of fining.
18. Insert tool into female connector, then push/pull inward to release locking tabs.
Notice: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
19. Pull connection apart.
20. Disconnect fuel pipe bracket at EGR valve.
21. Remove throttle body mount bolts.
22. Release locking tabs on fuel rail and pry each injector out of intake manifold using J 41081.
Fuel Rail Assembly And Intake Manifold:
23. Remove the fuel rail assembly.
Disassemble Procedure
1. Remove the injector harness.
Fuel Rail Assembly:
2. Remove the injectors from fuel rail.
3. Remove the upper and lower O-rings from injectors.
4. Discard the O-rings.
5. Clean the throttle body O-ring surfaces.
Assemble Procedure
1. Lubricate the new upper and lower injector O-rings with clean engine oil and install on injectors.
2. Install the injectors to fuel rail with new retainer clips. ensure injectors are aligned by orientating electrical connector perpendicular to crankshaft.
3. Install the injector harness.
Installation Procedure
1. Install the fuel rail with injectors to intake manifold.
2. Install the new throttle body gasket, throttle body, and throttle body mount bolts. Tighten the throttle body mount bolts to 12 Nm (106 lb in).
3. Install the new throttle body gasket, throttle body, and throttle body mount bolts. Tighten the throttle body mount bolts to 12 Nm (106 lb in).
4. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet pipes.
5. Install the quick-connect fittings to fuel rail.
6. Push both sides of fining together to cause the retaining tabs/fingers to snap into place.
7. Pull on both sides of fining to make sure connection is secure once installed.
8. Install throttle body spacer, new throttle body O-ring seal throttle body and mount bolts. Tighten the throttle body mount bolts to 12 Nm (106 lb in).
9. Install the fuel pressure regulator and crankcase ventilation vacuum lines.
10. Install the fuel rail ground wire at rear cylinder head.
11. Install the injector harness and injector electrical connectors.
12. Install the MAP sensor electrical connector.
13. Install the front bank spark plug wires.
14. Install the brake booster vacuum hose at intake manifold vacuum fitting.
15. Install the EGR pipe at throttle body spacer. Tighten the EGR pipe bolt to 28 Nm (21 lb in).
16. Install the air intake duct.
17. Tighten fuel filler cap.
18. Install the negative battery cable.
19. Inspect for leaks.
19.1. Turn the ignition switch ON for 2 seconds.
19.2. Turn the ignition switch OFF for 10 seconds.
19.3. Turn the ignition switch ON.
19.4. Check for fuel leaks.
20. Install the intake manifold top cover. Tighten the bolts to 2 Nm (18 in lb).