Fuel Rail: Service and Repair

REMOVAL

1. Disconnect battery ground 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 tank filler cap and release pressure.

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

4. Remove upper intake manifold.

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

6. Using Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 inch), D87L-9280-B (1/2 inch) or equivalent, disconnect the inlet and outlet fuel lines from the fuel injection supply manifold.

7. Remove fuel pressure regulator bracket retaining bolt.

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

Fuel Injection Supply Manifold:

NOTE: When installing fuel injection supply manifold with new or used fuel injectors, particular attention should be paid to proper 0-rings seating to ensure that no fuel leaks exist.

1. Push fuel injection supply manifold down to ensure all fuel injector 0-rings are fully seated in the fuel injection supply manifold cups and cylinder head pockets.

2. Install retaining bolts while holding fuel injection supply manifold down. Tighten to 8-11 Nm (71-97 lb in).

3. Install fuel pressure regulator bracket retaining bolt. Tighten to 20-30 Nm (15-22 lb ft).

4. Install inlet and outlet fuel lines spring lock couplings.

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

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

7. Connect fuel charging wiring.

8. Install upper intake manifold.

9. Run vehicle at idle for two minutes.

10. Turn engine OFF and inspect for leaks.