Fuel Rail: Service and Repair

Fuel Injection Supply Manifold:

REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel tank filler cap and release fuel tank pressure.
3. Perform fuel pressure release procedure. Service and Repair
4. Remove engine air intake resonators.
5. Disconnect fuel charging wiring from fuel injectors and position fuel charging wiring out of way.
6. Disconnect vacuum line at fuel pressure regulator.
7. Remove fuel line coupling retainer clip from fuel supply and return fittings.
8. Using Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 inch) or D87L-9280-B (1/2 inch) or equivalent, disconnect the fuel supply and return hoses from the fuel injection supply manifold.
9. Disconnect fuel supply and return hoses from retaining bracket on intake manifold.
10. Remove fuel injection supply manifold retaining bolts.
11. Carefully disengage fuel injection supply manifold with fuel injectors and remove fuel injection supply manifold.

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

12. Use light, twisting motion while removing fuel injectors and clip from fuel injection supply manifold.
13. Remove fuel injector clip from fuel injector.

INSTALLATION
1. Install fuel injectors into fuel injection supply manifold.

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

2. Push fuel injection supply manifold down to ensure all fuel injector O-rings are fully seated in the fuel injection supply manifold cups and lower intake manifold.
3. Install bolts while holding fuel injection supply manifold down. Tighten bolts to 8-12 Nm (71-106 lb in).
4. Connect the fuel supply and return hoses to the fuel injection supply manifold at the connectors. Install retaining clips over the connectors securely.
5. Install fuel supply and return hoses to bracket located on the intake manifold. Tighten retaining screw securely.
6. Connect vacuum line to fuel pressure regulator.
7. Connect battery ground cable.
8. With fuel charging wiring disconnected, turn ignition switch to the RUN position several times to allow the fuel pump to pressurize the fuel system.
9. Using a clean towel, check for fuel leaks.
10. Connect fuel charging wiring to fuel injectors.
11. Install engine air intake resonators.
12. Run vehicle at idle for two minutes.
13. Turn engine OFF and inspect for leaks.