Fuel Rail: Service and Repair

Idle Air Adjust Screw:

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Remove the upper manifold assembly, refer to UPPER MANIFOLD ASSEMBLY.
4. Remove the spring lock coupling retainer clip from the fuel inlet and return fittings.
5. Using the Spring Lock Coupling Disconnect Tool D87L-9280-A or B or equivalent, disconnect the crossover fuel hose from the fuel rail assembly.

NOTE: The following items should be observed when service is required:
^ Use the specified tool or equivalent.
^ Check for missing or damaged O-rings.
^ Lubricate the O-rings with clean engine oil.
^ Make sure fittings are locked.

6. Remove the four fuel rail retaining bolts.
7. Disengage the fuel rail from the injectors and remove the fuel rail.

NOTE: It may be easier to remove the injectors with the fuel rail as an assembly.

8. Use a rocking motion, from side to side while lifting to remove the injectors from the fuel rail.

Bypass Air Control Valve:

INSTALLATION:

1. Push the fuel rail down to ensure all injector O-rings are fully seated in the fuel rail cups and the intake manifold.
2. While holding the fuel rail down, instal the bolts and tighten to 8.0-12.0 Nm (70-105 lb.in).
3. Install the spring lock coupling.
4. With the injector wiring disconnected, turn the ignition to the RUN position to allow the fuel pump to pressurize the fuel system.
5. Check for fuel leaks.
6. Connect the injector electrical connectors. Run the vehicle for two minutes.
7. Check for fuel leaks again.