Fuel Injector: Service and Repair

FUEL RAIL

Exploded View

















Removal and Installation

WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury.

With the vehicle in NEUTRAL, position it on a hoist.

2. Release the fuel system pressure.
3. Disconnect the battery ground cable.
4. Disconnect the fuel tube spring lock coupling from the fuel rail.
5. Remove the throttle body (TB).
6. Remove the EGR system module tube.
7. Disconnect the brake booster vacuum hose from the TB spacer and position aside.
8. Disconnect the evaporative emission (EVAP) canister purge valve hose quick connect coupling from the TB spacer and position aside.
9. Disconnect the PCV tube quick connect coupling from the TB spacer and position aside.
10. Disconnect the intake manifold vacuum hose from the TB spacer and position aside.
11. If equipped, detach the crash bracket wire harness retainer.
12. Remove the 2 crash bracket bolts and the bracket.
- To install, tighten to 25 Nm (18 lb-ft).

13. Remove the wire harness retainer from the LH front fuel rail stud bolt and position aside.
14. Disconnect the 8 fuel injector electrical connectors.
15. Disconnect the ground connector from the RH rear fuel rail stud bolt and position aside.
16. Disconnect the fuel rail pressure and temperature sensor vacuum hose and electrical connector.
17. Disconnect the EGR system module vacuum and electrical connectors.
18. Remove the 2 intake manifold shield bolts and the shield.
- To install, tighten to 12 Nm (9 lb-ft).

19. Remove the 4 fuel rail stud bolts.
- To install, tighten to 10 Nm (89 lb-in).

20. Remove the fuel rail and the fuel injectors as an assembly.

21. CAUTION: Use O-rings seals that are made of special fuel-resistant material. Use of ordinary O-ring seals can cause the fuel system to leak. Do not reuse O-ring seals.

Separate the fuel injectors from the fuel rail.
- Discard the O-ring seals.

22. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury.

To install, reverse the removal procedure. If equipped with fire suppression system, repower the system.
- Lubricate the fuel injectors O-ring seals with clean engine oil prior to installation.