Fuel Rail: Service and Repair
TOOLS REQUIRED^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Fuel Line Quick-Connect Separator
^ J 41081 Injector Remover
REMOVAL PROCEDURE
NOTE:
^ Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dint and other contaminants from entering open pipes and passages.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the intake air duct clamp (2) from the air cleaner assembly (3).
3. Remove the intake air duct clamp (5) from the MAF sensor (4).
4. Disconnect the MAF sensor electrical connector from the MAF sensor (4).
Description:
5. Remove the EGR pipe and crankcase ventilation pipe at throttle body spacer.
Fuel Injector Above Intake Port:
6. Remove the brake booster vacuum hose at intake manifold.
7. Remove the front bank spark plug wires.
8. Disconnect the fuel injector harness electrical connectors from the fuel injectors.
9. Remove the transaxle vent hose (2) from the clip attached to the accelerator control cable (1).
Description:
10. Remove the fuel pressure regulator vacuum line from the fuel pressure regulator.
Description:
11. Remove the fuel rail ground wire (1) nut at the rear cylinder head.
12. Disconnect the quick-connect clips (4), (5) from the fuel pipes (engine side).
13. Disconnect the fuel feed (2) and fuel return (3) quick-connect fittings at fuel rail.
Fuel Rail Assembly And Intake Manifold:
14. Disconnect fuel pipe bracket at the EGR valve if applicable.
15. Remove throttle body mount bolts.
16. Remove the throttle body spacer bolts.
17. Release locking tabs on fuel rail and pry each injector out of intake manifold using J 41081.
18. Remove the fuel rail assembly.
19. Disconnect the canister purge vacuum hose
20. Remove the MAP sensor.
DISASSEMBLE PROCEDURE
Description:
1. Remove the injector harness.
2. Spread the injector retaining clip(s) (10) to release the injector(s) (12) from the fuel rail assembly.
3. Remove the injector(s) (12) from fuel rail.
4. Remove the upper (11) and lower (13) O-ring(s) from injector(s).
5. Discard the O-rings.
6. Clean the throttle body O-ring surfaces.
ASSEMBLE PROCEDURE
Description:
1. Lubricate the new upper (11) and lower (13) injector O-ring(s) with clean engine oil.
2. Install the new upper (11) and lower (13) injector O-ring(s) on the injector(s) (12).
3. Install the injector(s) (12) to fuel rail with new retainer clip(s) (10).
4. Ensure the injector(s) (12) are aligned by orientating the electrical connector perpendicular to the crankshaft.
5. Connect the injector harness.
INSTALLATION PROCEDURE
Fuel Rail Assembly And Intake Manifold:
1. Reinstall the fuel rail with injector(s) to intake manifold.
2. A snap will be heard when the injectors are properly seated.
Description:
3. Reinstall the throttle body spacer gasket and throttle body spacer (3) to the intake manifold (4).
NOTE: Refer to the Fastener Notice in Service Precautions.
4. Tighten the bolts.
5. Install the new throttle body gasket (2), throttle body (1), and bolts.
6. Tighten the bolts.
Tighten
Tighten the bolts to 12 N.m (106 lb in).
NOTE: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
7. Clean the quick-connect fittings.
8. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet pipes.
9. Connect the quick-connect fittings to fuel rail.
10. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
11. Pull on both sides of fitting to make sure connection is secure once installed.
12. Repeat Steps 8 through 12 for the other fitting.
13. Reinstall the quick-connect clips to the fuel pipes (engine side).
14. Reinstall the fuel pipe bracket at the EGR valve if applicable.
Description:
15. Connect the fuel pressure regulator and crankcase ventilation vacuum lines.
NOTE: Refer to the Fastener Notice in Service Precautions.
Description:
16. Connect The fuel rail ground wire (1) at rear cylinder head.
Tighten
Tighten the fuel rail ground wire bolt to 11 N.m (97 lb in).
17. Tighten the fuel rail assembly bolt to 8 N.m (71 lb in).
Description:
18. Connect the injector harness and injector electrical connectors.
19. Reinstall the front bank spark plug wires.
20. Connect the brake booster vacuum hose at intake manifold vacuum fitting.
21. Connect the EGR pipe at throttle body spacer.
Tighten
Tighten the EGR pipe bolt to 28 N.m (21 lb ft).
22. Connect the MAF sensor (4) electrical connector.
23. Reinstall the intake air duct (1) clamp (5) from the MAF sensor (4).
24. Reinstall the intake air duct (1) clamp (2) from the air cleaner assembly (3).
25. Add fuel to the tank.
26. Tighten fuel filler cap.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
27. Connect the negative battery cable.
28. Inspect for leaks.
28.1. Turn the ignition switch ON for 2 seconds.
28.2. Turn the ignition switch OFF for 10 seconds.
28.3. Turn the ignition switch ON.
28.4. Check for fuel leaks.
29. Reinstall the intake manifold sight shield.