Fuel Rail: Service and Repair

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

CAUTION: If the supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the supply manifold.

1. Remove the intake manifold.
2. Disconnect the fuel hose spring lock coupling.







3. Remove the bolt and the bracket.







4. Disconnect the right side fuel injector electrical connectors and the two wiring harness retainers.







5. Disconnect the left side fuel injector electrical connectors and the wiring harness retainers.







6. Disconnect the fuel pulse damper vacuum hose.







7. Remove the fuel injection supply manifold.







8. If necessary, remove the bolts and the fuel supply tube.
^ Discard the O-rings.







9. Remove and discard the fuel injector-to-supply manifold O-rings.

INSTALLATION
1. To install, reverse the removal procedure.
^ Install new O-ring seals and lubricate them with clean engine oil.

CAUTION: O-ring seals are made of special fuel resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse the O-ring seals.