Fuel Rail: Service and Repair

Warning: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component.

Removal

1. Release fuel system pressure. Service and Repair

Fuel Injector Harness Connections:

2. Disconnect negative battery cable and remove air cleaner assembly.
3. Disconnect fuel injector harness electrical connector and detonation (knock) sensor electrical connector.

Electrical, Fuel, And Vacuum Connections:

4. Disconnect the Quick-Connect fittings from the chassis fuel tubes.
5. Disconnect the vacuum, vapor hose connection.
6. Disconnect the fuel pressure regulator vacuum hose at the regulator.

Fuel Rail Attaching Screws:

7. Remove the fuel tube clamp screw.
8. Remove the fuel rail mounting bolts.
9. Remove the fuel rail and injector assembly by pulling the rail so that the injectors come straight out of their ports.
10. Inspect injector O-rings upon removal and discard any that appear damaged or worn.
11. Cover fuel injector ports while injectors are removed.
12. Do not disassemble the fuel rail until it has been removed from the vehicle.

Fuel Rail And Injector Assembly:

Installation

1. Be certain injectors are seated into receiver cups and retainer rings are in place before attempting to install fuel rail assembly.
2. Install injector wiring harness into injectors and fasten into wiring clips. Make sure injector ports are clean and any plugs have been removed.
3. Lube injector O-rings with clean motor oil and install the injector/rail assembly into the injector ports. Install the 2 fuel rail mounting bolts and ground straps. (Make sure fuel rail seats evenly with all injectors seated in their ports.) Torque mounting bolts to 200 lb-in (22.5 Nm).

Fuel Injector Harness Connections:

4. Connect detonation (knock) sensor electrical connector.
5. Connect vacuum hose to fuel pressure regulator.
6. Close fuel tube clamp around fuel tubes and mount the clamp screw to the manifold.
7. Connect the fuel injector electrical connector to the main engine harness.
8. Lubricate the chassis fuel tubes with clean engine oil and connect the Quick-Connect fuel fittings. After the fittings have been installed, pull back on them to make sure they are securely attached.
9. Install air cleaner and connect negative battery cable.

Note: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless the test is stopped or the ignition switch is turned to the OFF position.

10. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto Shutdown (ASD) Relay", to activate fuel pump and pressurize system.
11. Check for leaks.