Fuel Rail: Service and Repair

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
2. Disconnect the negative battery cable.
3. Remove intake manifold plenum. Refer to the Engine section for information.
4. Remove intake manifold plenum mounting bolts. Lift Plenum up off of engine. Cover intake manifold to prevent foreign material from entering engine.
5 Disconnect fuel supply tube quick connect fitting at the rear of the fue rail. Refer to Quick Connect Fittings in the Fuel Delivery Section.

Injector Electrical Connectors:

6. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
7. Remove electrical connectors from the fuel injectors.
8. Remove mounting bolts on both sides of fuel rail.
9. Lift fuel rail straight up off of cylinder head.
10. Remove retaining clips from fuel injectors at fuel rail.
11. Remove fuel injector from fuel rail.

INSTALLATION
1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
2. Install retaining clips on fuel injectors.
3. Push injectors into fuel injector rail until clips are in the correct position.
4. Position fuel rail over cylinder heads, and push rail into place. Tighten fuel rail mounting bolts to 11.9 Nm (105 in. lbs.) torque.
5. Connect the fuel supply tube quick connect fitting to the fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery Section.
6. Connect the electrical connectors to the fuel injectors.
7. Install intake manifold plenum. Refer to the Engine section for information.
8. Connect negative cable to battery.