Fuel Rail: Service and Repair

Fuel Injectors And Related Components:

REMOVAL

1. Disconnect battery ground cable and secure it out of the way.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy.

2. Remove fuel cap.

3. Release pressure from fuel system.

4. Remove upper intake manifold.

5. Remove spring lock coupling retaining clips from fuel inlet and return fittings.

6. Using Spring Lock Coupling Disconnect Tool D87L-9280-A, D87L-9280-B or equivalent disconnect the inlet and outlet fuel lines from the fuel injection supply manifold.

7. Remove four fuel injection supply manifold retaining bolts (two on each side). Remove fuel pressure regulator bracket retaining bolt from cylinder head.

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

8. Carefully disengage fuel injection supply manifold from fuel injectors and remove fuel injection supply manifold.

9. Use a rocking, side-to-side motion while lifting to remove fuel injectors from cylinder head pockets.

INSTALLATION

1. Push fuel injection supply manifold down to ensure all fuel injector O-rings are fully seated in the fuel injection supply manifold cups and cylinder head pockets.

CAUTION: When installing fuel injection supply manifold, particular attention should be paid to proper 0-ring seating to ensure no fuel leaks exist.

2. Install retaining bolts while holding fuel injection supply manifold down. Tighten fuel injection supply manifold retaining bolts to lower intake manifold to 8-11 Nm (71-97 lb in). Tighten fuel pressure regulator bracket retaining bolt to cylinder head to 20-30 Nm (15-22 lb ft).

3. Install spring lock coupling.

4. With fuel charging wiring disconnected, turn ignition switch to the RUN position several times, to allow the fuel pump to pressurize the system.

5. Using a clean towel, check for fuel leaks.

6. Connect fuel charging wiring.

7. Install upper intake manifold.

8. Run vehicle at idle for two minutes. Turn engine OFF and inspect for leaks.