Fuel Rail: Service and Repair

REMOVAL
1. Perform fuel system pressure release procedure before servicing or starting repairs. Refer to Fuel System Pressure Release Procedure.
2. Disconnect negative cable from battery.

Fuel Rail And Bracket:

3. Remove wiring harness from fuel rail support bracket.
4. Remove fuel rail support bracket.

Fuel Rail And Injectors:

5. Disconnect the wiring connectors for fuel injectors harness.
6. Remove wiring harness from fuel rail brackets.
7. Disconnect the connectors from the fuel injectors.

Throttle And Speed Control Cable:

8. Remove throttle and speed control cables from the fuel rail.
9. Remove fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. Place a shop towel under the connections to absorb any fuel spilled from the fitting.

WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

10. Remove fuel rail attaching bolts.
11. Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports.

INSTALLATION
1. Ensure injector holes are clean. Replace O-rings if damaged.
2. Lubricate injector O-rings with a drop of clean engine oil to ease installation.
3. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
4. Install the 2 fuel rail mounting bolts to intake manifold. Tighten bolts to 11.9 Nm (105 in. lbs.) torque.
5. Install the fuel rail mounting bolt to cylinder head. Tighten bolt to 22 Nm (195 in. lbs.) torque
6. Connect the connectors to the fuel injectors.
7. Install fuel rail support bracket and loosely install all bolts.
8. Tighten three fasteners to intake manifold to 28.3 Nm (250 in. lbs.) torque.
9. Tighten two bolts to fuel rail to 8.5 Nm (75 in. lbs.) torque.
10. Install wiring harness to brackets.
11. Connect the throttle and speed control cables to fuel rail bracket.
12. Connect negative battery cable.
13. Use the DRBIII(R) scan tool to pressurize the fuel system. Check for leaks.