Fuel Rail: Service and Repair

REMOVAL PROCEDURE





TOOLS REQUIRED
^ J 34730 - 1A Fuel Pressure Gauge
^ J 37088-A Fuel Line Quick-Connect Tools
^ J41081 Injector Remover

NOTE:
^ Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

1. Relieve fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Remove the air intake duct.




3. Remove the EGR pipe at throttle body spacer.
4. Remove the brake booster vacuum hose at intake manifold vacuum fitting.
5. Remove the front bank spark plug wires.




6. Remove the MAP sensor electrical connector (1) from the MAF sensor (2).




7. Remove the fuel injector electrical connectors from the fuel injectors.




8. Lay the harness aside.
9. Remove the fuel rail ground wire (7) bolt at the rear cylinder head.
10. Remove the fuel pressure regulator (1) from the fuel rail.




11. Remove the crankcase ventilation vacuum lines.




12. Remove the quick-connect fittings (2) at the fuel rail.
13. Remove the fuel rail end-point bracket retainer bolt.




14. Remove the throttle body mount bolts.
15. Remove the throttle body.
16. Remove the throttle body spacer (3).
17. Remove the intake manifold to throttle body spacer O-ring seal.




18. Release the locking tabs (8) on fuel rail by pushing toward center of intake manifold and pry each injector out of intake manifold using J 41081.




19. Lift the fuel rail and move the fuel rail toward the left hand side of the vehicle until the fuel pipes clear the intake plenum.
20. An eight digit identification number is stamped on the fuel rail assembly. The model identification number contains the Julian Date, the year, and the shift. Refer to this model identification number if servicing or part replacement is required.

DISASSEMBLY PROCEDURE




1. Remove the fuel injector harness.




2. Remove the clips (3) from the injectors (5) on the fuel rail.




3. Remove the upper (3) and lower (2) seals from the injector(s) (1).
4. Discard the seals after removal.

ASSEMBLE PROCEDURE




1. Lubricate the upper (6) and lower (4) injector O-rings with clean oil and install the O-rings on to the fuel injectors.




2. Assemble the injectors to the fuel rail with new retainer clips.
3. Assemble the injector harness.

INSTALLATION PROCEDURE




1. Install the fuel rail with injectors to intake manifold.
2. The fuel injectors are fully seated when a snap is heard.





NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the new O-ring seal between the throttle body spacer (3) and intake manifold (4).
4. Install throttle body spacer (3).

Tighten
Tighten the throttle body spacer bolts to 12 N.m (106 lb in).

5. Install the new throttle body gasket (2) between the throttle body (1) and throttle body spacer (3).
6. Install the throttle body (1).

NOTE: Refer to Fastener Notice in Service Precautions.

7. Install the throttle body mount bolts.

Tighten
Tighten the throttle body mount bolts to 12 N.m (106 lb in).




8. Install the fuel pressure regulator if the fuel pressure regulator was removed from the fuel rail.




9. Install the crankcase ventilation vacuum lines.




10. Install the fuel rail ground wire at rear cylinder head (7).

Tighten
Tighten the fuel rail ground wire bolt to 6 N.m (53 lb in).




11. Install the fuel injector electrical connector(s).




12. Install the MAP sensor electrical connector (1) to the MAF sensor (2).
13. Install the front bank spark plug wires.
14. Install the brake booster vacuum hose at intake manifold vacuum fitting.




15. Install the EGR pipe at throttle body spacer.

Tighten
Tighten the EGR pipe bolt to 24 N.m (18 lb in).




16. Install the fuel rail end-point bracket (1) retainer bolt (2).

Tighten
Tighten the bolt to 11 N.m (97 lb in).




17. Install the air intake duct.

Tighten
Tighten the clamp(s) to 3.5 N.m (31 lb in) at the MAF sensor and 1.8 N.m (16 lb in) at the air cleaner.




18. Tighten fuel filler cap (1).
19. Install the negative battery cable.
19.1. Turn ignition switch to the On position for 2 seconds.
19.2. Turn the ignition switch OFF for 10 seconds.
19.3. Turn the ignition switch ON.
19.4. Check for fuel leaks.




20. Install the rear seat cushion.
21. Install the intake manifold top cover.

Tighten
Tighten the nuts to 3 N.m (27 lb in).