Fuel Rail: Service and Repair

REMOVAL
1. Fuel system pressure must be released prior to service. Service and Repair
2. Disconnect negative battery cable, and remove air cleaner to throttle body hose.
3. Remove throttle cable. Remove wiring harness from the throttle cable bracket and intake manifold water tube.
4. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. Remove vacuum hose harness from throttle body, and PCV and brake booster hoses from air intake plenum.
5. Remove wiring connector from charge temperature sensor. Remove EGR tube flange and vacuum connections from intake plenum. Remove fuel hoses from fuel rail.

Quick Connect Fittings:

6. Remove intake plenum to cylinder head strut. Disconnect oxygen sensor connector, Manifold Absolute Pressure (MAP) sensor connector and engine ground strap.
7. Remove the Direct Ignition System (DIS) coils and alternator to intake manifold bracket bolt.

Intake Manifold Bolt Location:

8. Remove all 4 intake plenum to intake manifold fasteners, and move plenum back over the rear valve cover. Cover intake manifold ports before proceeding.
9. Disconnect fuel pressure regulator vacuum harness. Remove fuel tube retainer bracket and fuel rail attaching bolts.
10. Spread retainer brackets and remove injector wiring clip from the alternator bracket.

Fuel Rail Bolt Location (Intake Plenum Removed):

11. Disconnect cam sensor, coolant temperature sensor and engine temperature sensor connectors.
12. Remove fuel rail, using care to avoid damaging injectors or injector O-rings.

Fuel Rail Removal:

INSTALLATION
1. Make sure injectors are seated into fuel rail receiver cups, and injector lock clips are in place. Check injector holes to make sure they are clean and any plugs have been removed. Lube injector O-rings with clean engine oil prior to installation.
2. Place the tip of each injector in its respective port and push the rail assembly into place until all injectors are seated in the ports. Install the fuel rail attaching bolts and torque to 22 Nm (200 lb-in).
3. Install the fuel tube retaining bracket and torque to 4 Nm (35 lb-in).
4. Connect cam sensor, coolant temperature sensor and engine temperature sensor. Install injector wiring harness clips to the alternator bracket and intake manifold water tube.
5. Connect fuel pressure regulator vacuum hose. Remove covering from intake manifold, and clean surface.
6. Place intake manifold gaskets on lower manifold. Install intake plenum and hand tighten fasteners.
7. Install the alternator bracket to intake manifold bolt, and the cylinder head to intake manifold strut bolts, (do not torque at this time).

Intake Manifold Bolt Location:

8. Torque intake manifold bolts to 28 Nm (250 lb-in). Follow torque sequence in image above.
9 Torque alternator bracket to intake manifold, and cylinder head to intake manifold bolts to 54 Nm (40 lb-ft).
10. Connect ground strap, MAP sensor, charge temperature sensor and oxygen sensor connectors.
11. Install DIS coils and torque bolts to 12 Nm (105 lb-in).
12. Connect fuel lines to fuel rail and torque clamps to 1 Nm (10 lb-in). Connect vacuum harness to air intake plenum and fuel pressure regulator.
13. Connect brake booster supply hose to intake plenum and connect PCV hose to plenum. Connect AIS motor and TPS electrical connectors, and connect vacuum harness to throttle body.
14. Install throttle cable, and air inlet hose assembly. Connect negative battery cable.
15. Pressurize fuel system and check for leaks. Fuel System Pressurizing Procedure