Fuel Rail: Service and Repair

Fuel Injection Supply Manifold:

REMOVAL

1. Remove throttle body assembly.

2. Scribe an alignment mark on the base of the distributor and the intake manifold. Remove distributor hold-down clamp and lift distributor enough to allow fuel injection supply manifold to clear distributor and intake manifold.

3. Disconnect the fuel supply and return lines.

4. Carefully disconnect wiring harness from fuel injectors.

5. Disconnect vacuum line from the fuel pressure regulator.

6. Remove four fuel injector supply manifold retaining bolts.

7. Carefully disengage fuel injection supply manifold assembly from fuel injectors by lifting and gently rocking the rail.

8. Remove fuel injectors by lifting while gently rocking side to side.

9. Place removed components in clean container to avoid dirt or other contamination.

INSTALLATION

1. Examine injector O-ring for deterioration. Install new O-rings if required.

2. Lubricate new O-ring and install two on each injector using clean engine oil.

3. Ensure fuel injector cups are clean and free of contamination or damage.

4. Install fuel injectors in fuel injector supply manifold using light twisting-pushing motion.

5. Prior to installation of manifold perform the following:

a. Lift the distributor enough to allow fuel injection manifold crossover tube to clear distributor and intake manifold and position fuel injection supply manifold.

b. Lower distributor into position.

c. Install distributor hold-down clamp and align scribe marks. Tighten hold-down clamp bolt to 24 Nm (18 lb in).

6. Carefully install fuel injection supply manifold assembly and fuel injectors into lower intake manifold, one side at a time. To ensure that O-rings are seated, push down on fuel injection supply manifold firmly.

7. While holding fuel injection supply manifold assembly in place, install two retaining bolts. Torque to 8.0-12.0 Nm (71-106 lb in).

8. Connect spring lock coupling fuel supply and fuel return lines.

9. Before connecting the fuel charging wiring harness, turn the ignition switch ON position several times. this will pressurize the fuel system.

10. Using a clean paper towel, check for leaks where the fuel injectors connect to the fuel injection supply manifold.

11. Connect the fuel charging wiring harness to fuel injectors.

12. Install throttle body.

13. Start engine, allow to idle and check for fuel leaks. Service as necessary.