Fuel Rail: Service and Repair

Fuel Rail Assembly:

CAUTION:
- Use care in removing the fuel rail assembly to prevent damage to the injector electrical connector terminals and the injector spray tips. When removed, support the rail to avoid damaging its components.
- Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped, and holes plugged, during servicing.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.
- Refer to Fuel System / Service and Repair. Service and Repair
2. Air intake duct.
3. EGR pipe at EGR transfer spacer.
4. Brake booster vacuum pipe at intake manifold vacuum hose.
5. Front bank spark plug wires.
6. Injector electrical connectors.
7. Fuel rail ground wire at rear cylinder head.
8. Fuel pressure regulator and crankcase ventilation vacuum lines.
9. Quick-connect fittings at fuel rail:

A. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

B. Using compressed air, blow dirt out of fitting.
C. Squeeze plastic retainer release tabs.
D. Pull connection apart.

Clean and Inspect

CAUTION: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to O-ring sealing surface.

- Using a clean shop towel, wipe off male pipe end.
- Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.

10. Fuel line bracket at engine lift hook.
11. Release locking tabs on fuel rail and pry each injector out of intake manifold using j 41081.
12. Fuel rail assembly.

DISASSEMBLE
1. Injectors from fuel rail.
2. Upper and lower seals from injectors. Discard seals.

ASSEMBLE
1. Lubricate new upper and lower injector O-rings with clean engine oil and install on injectors.
2. Injectors to fuel rail with new retainer clips.

INSTALL OR CONNECT
1. Fuel rail with injectors to intake manifold.
2. Quick-connect fittings to fuel rail:

A. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
B. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
C. Once installed, pull on both sides of fitting to make sure connection is secure.

3. Fuel line bracket at engine lift hook.
4. Fuel pressure regulator and crankcase ventilation vacuum lines.
5. Fuel rail ground wire at rear cylinder head.
6. Injector electrical connectors.
7. Front bank spark plug wires.
8. Brake booster vacuum pipe at intake manifold vacuum hose.
9. EGR pipe at EGR transfer spacer.
10. Air intake duct.
11. Tighten fuel filler cap.
12. Negative battery cable.

Inspect
- Turn ignition switch to the "ON" position for two seconds, then turn to the "OFF" position for ten seconds. Again turn to the "ON" position and check for fuel leaks.

13. Rear seat cushion.
14. Intake manifold top cover.