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 upper intake manifold.

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 spring lock coupling retainer clip from fuel supply and return fittings.

8. Using Spring Lock Coupling Disconnect Tool D87L-9280-A (3/8 inch) or B D87L-9280-B (1/2 inch) 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 resistant O-rings (Brown).

- Lubricate the O-rings with clean engine oil.

- Check to ensure that the fittings are locked.

9. Remove seven fuel injection supply manifold retaining bolts.

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

10. Remove IMRC vacuum solenoid linkage rod from lower intake manifold by carefully prying rod with screwdriver. Replace the IMRC linkage rod bushings prior to reassembly.

Fuel Injection Supply Manifold:

11. Carefully disengage fuel injection supply manifold with fuel injectors and remove fuel injection supply manifold and fuel injector seals. Discard the seals.

12. Using Injector Remover T94P-9000-AH, remove fuel injectors from fuel injection supply manifold.

INSTALLATION

1. Install fuel injectors into fuel injection supply manifold.

NOTE: The fuel injector seals must be replaced anytime the fuel injection supply manifold is removed from the intake manifold.

2. Install new fuel injector seals between the fuel injection supply manifold and the lower intake manifold, and install the fuel injection supply manifold.

3. Install fuel injector retainers and bolts while holding fuel injection supply manifold down. Verify proper installation of fuel injector retainers and tighten bolts to 8-12 Nm (71-106 lb in).

NOTE: Replace IMRC linkage rod bushings before installing linkage rod.

4. Install IMRC vacuum solenoid linkage rod to lower intake manifold.

5. Install spring lock couplings.

6. Connect vacuum line to fuel pressure regulator.

7. Connect battery ground cable.

8. Install fuel pressure gauge.

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

NOTE: Make sure the fuel system maintains pressure. If a loss of pressure is noted, the fuel injector O-rings may be damaged or incorrectly installed, allowing excess fuel to leak into the cylinders. In this case, disassemble the system and repair the problem before starting the engine.

10. Connect fuel charging wiring to fuel injectors.

11. Install upper intake manifold.

12. Run vehicle at idle for two minutes.

13. Turn engine OFF and inspect for leaks.