Fuel Rail: Service and Repair

REMOVAL:

1. Disconnect the negative battery cable.
2. Disconnect the cold start injector fuel pipe.
3. Disconnect the vacuum sensing hose from the Fuel Pressure Regulator. Disconnect electrical connectors from injectors.
4. Disconnect the fuel hose from the fuel return pipe.
5. Using a wrench, remove the Fuel Pressure Pulsation Damper along with the two sealing gaskets.

Removing Fuel Pressure Pulsation Damper:

6. Remove the two Fuel Rail mounting bolts.

Removing Fuel Rail:

7. Lift the Fuel Rail with the injectors from the cylinder head.

CAUTION: Be careful that the injectors do not drop from the Fuel Rail. Damage to the injector tip could result.

8. Remove the four insulators and two spacers from the cylinder head.
9. When the Fuel Rail is safely over a workbench, pull the injectors from the Fuel Rail.

INSTALLATION:

1. Install new grommet and O-ring on each removed injector.

Fuel Injector O-Ring:

2. Apply a light coat of gasoline to the O-ring to ease insertion into the Fuel Rail.
3. With a twisting motion, install each injector into the Fuel Rail until fully seated. Carefully check proper alignment to prevent fuel leaks.

Correct Installation Of Fuel Injectors To Fuel Rail:

4. Place four new insulators and two spacers in position on the cylinder head.

Fuel Rail Insulators And Spacers:

5. Carefully install the Fuel Rail with injectors on the cylinder head.
6. Start the two mounting bolts, but do not tighten. Rotate each injector to ensure that there is no binding of the sealing parts.

Installing Fuel Rail With Fuel Injectors:

7. If the injectors do not rotate smoothly, recheck the O-rings for correct installation.
8. Position injector connector sockets facing up.
9. Torque the two mounting bolts to 9 ft.lbs. (13 N-m).
10. Install the Fuel Pressure Pulsation Damper using two new gaskets.

Fuel Pressure Pulsation Damper:

11. Connect the fuel return hose.
12. Connect injector electrical connectors.
13. Connect vacuum sensing hose to the Fuel Pressure Regulator.
14. Connect cold start injector fuel delivery pipe with two new gaskets. Torque the union bolt to 13 ft.lbs. (18 N-m).
15. Reconnect negative battery cable.
16. Start engine and check for fuel leaks.