Fuel Rail: Service and Repair

REMOVAL

1. Verify fuel rail assembly is depressurized by removing fuel tank cap and releasing pressure from fuel system at pressure relief valve on fuel rail assembly using a fuel pressure gauge.
2. Remove fuel cap.
3. Disconnect battery ground cable and secure it out of the way.
4. Remove upper intake manifold, see UPPER INTAKE MANIFOLD.
5. Remove spring lock coupling retainer clip from fuel inlet and return fittings.
6. Disconnect the crossover fuel hose from the fuel rail assembly.
7. Remove four fuel rail assembly retaining bolts (two on each side).
8. Carefully disengage fuel rail from fuel injectors and remove fuel rail.
NOTE: It may be easier to remove injectors with the fuel rail as an assembly.
9. Use a rocking, side to side motion while lifting to remove the injectors from the fuel rail.

INSTALLATION

Fuel Injection Supply Manifold:

1. Push fuel rail down to ensure all injector O-rings are fully seated in the fuel rail cups and intake manifold.
2. Install retaining bolts while holding fuel rail down. Tighten to 70-105 lb. in. (8-12 N-m).
3. Install spring lock couplings.
4. With injector wiring disconnected, turn ignition to the RUN position to allow the fuel pump to pressurize the system.
5. Check for leaks using a clean towel.
6. Connect fuel injector wiring harness. Run vehicle at idle for two minutes.
7. Turn engine OFF and inspect for leaks.