Fuel Rail: Service and Repair
FUEL INJECTION SUPPLY MANIFOLDREMOVAL
All vehicles
WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury.
1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Disconnect the fuel lines.
4. Remove the throttle body.
5. On gasoline engines, remove the EGR valve to exhaust manifold tube.
6. Remove the drive belt.
Vehicles equipped with natural gas engines
7. Disconnect the fuel temperature sensor connector.
8. Disconnect the fuel pressure sensor connector.
All vehicles
9. Disconnect the main fuel shut-off solenoid connector.
10. Disconnect the generator cable, the electrical connector and the harness pin-type retainer.
11. Remove the bolts and the generator mounting bracket.
12. Remove the bolts, the return spring, and disconnect the accelerator and speed control cables.
13. Unclip the accelerator cable and the speed control actuator cable from the two crash brackets and position aside.
14. Separate the fuel charging wiring pin-type retainer from the crash bracket.
15. NOTE: On natural gas vehicles, there are no EGR vacuum connections.
Disconnect the vacuum lines and the electrical connector and position aside.
16. Remove bolt and stud and remove the crash bracket.
17. Disconnect the ground connector from the RH rear stud.
18. Disconnect generator harness locator retainer from LH front stud.
19. Disconnect the eight fuel injector electrical connectors.
20. Disconnect the crankcase ventilation tube and position out of the way.
Vehicle equipped with gasoline engines
21. Disconnect the vacuum line and the electrical connector.
22. Disconnect the vacuum line from the evaporative emission (EVAP) canister purge valve.
All vehicles
23. Remove the four studs.
24. Remove the fuel injection supply manifold and the fuel injectors as an assembly.
INSTALLATION
All vehicles
1. CAUTION: Use O-ring that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings.
NOTE: Natural gas fuel injectors are identified by an aqua cap.
Lubricate the fuel injector pockets with clean engine oil to aid installation.
2. Install the fuel injection supply manifold and the fuel injectors as an assembly.
3. Tighten the fuel injection supply manifold studs to specification.
4. Install the crash bracket.
5. Install the bolt and the stud.
Vehicles equipped with gasoline engines
6. Connect the vacuum line to the evaporative emission canister purge valve.
7. Connect the vacuum line and the electrical connector.
All vehicles
8. Connect the crankcase ventilation tube.
9. Connect the eight fuel injector electrical connectors.
10. NOTE: On natural gas engines there are no EGR vacuum connections.
Connect the vacuum lines and the electrical connector.
11. Install fuel charging pin-type retainer to the crash bracket.
12. Clip the accelerator cable and the speed control actuator cable to the two crash brackets.
13. Connect the accelerator and speed control cables, the return springs, and install the bolts.
14. Install the generator mounting bracket and tighten the bolts.
Vehicles equipped with natural gas engines
15. Connect the generator cable, the electrical connector and the harness pin-type retainer.
16. Connect the main fuel shut-off solenoid connector.
17. Connect the fuel pressure sensor connector.
18. Connect the fuel temperature sensor connector.
All vehicles
19. Connect ground connector to RH rear stud.
20. Connect the generator harness location retainer to the LH front stud.
21. Install the drive belt.
22. On gasoline engines, install the EGR valve to exhaust manifold tube.
23. Install the throttle body.
24. Connect the fuel lines.
25. Connect the battery ground cable.