Fuel Rail: Service and Repair

REMOVAL

1. Disconnect negative battery cable.

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 filler cap and release fuel tank pressure.

3. Relieve fuel system pressure, refer to Service and Repair / Fuel Pressure Relief Procedure.

4. Remove air cleaner outlet tube from throttle body.

5. Disconnect vacuum line at fuel pressure regulator.

6. Remove spring lock coupling retainer clip from fuel inlet and return fittings.

7. Using Spring Lock Coupling Disconnect Tool D87L-9280-A or B or equivalent, disconnect the fuel supply and return hoses from the fuel injection supply manifold.

NOTE: The following items should be noted when service is required:

- Use specified tool or equivalent.

- Inspect for missing or damaged O-rings.

- Use the specified fuel resistant O-rings (Brown).

- Lubricate the O-ring with clean engine oil.

- Check to ensure that the fitting is locked.

8. Disconnect fuel charging wiring from fuel injectors.

9. Remove four fuel injection supply manifold retaining bolts (two on each side).

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

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

11. Use a rocking, side-to-side motion while lifting to remove fuel injectors from fuel injection supply manifold.

INSTALLATION

Fuel Supply Manifold:

NOTE: When installing fuel injection supply manifold particular attention should be paid to proper seating of fuel injector O-rings to ensure that no fuel leaks exist.

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 intake manifold.

2. Install retaining bolts while holding fuel injection supply manifold down. Tighten retaining bolts to 8-12 Nm (71-106 lb in).

3. Install spring lock coupling.

4. Connect vacuum line to fuel pressure regulator.

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

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

7. Connect fuel charging wiring to fuel injectors.

8. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 2.5-3.2 Nm (22-28 lb in).

9. Connect negative battery cable.

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