Fuel Rail

Fuel Rail





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.

WARNING: 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.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. 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. Procedures

With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Release the fuel system pressure. For additional information, refer to Fuel System - General Information Service and Repair.

3. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

4. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to Fuel System - General Information Service and Repair.

5. Remove the Throttle Body (TB). For additional information, refer to Throttle Body Service and Repair.

6. Remove the EGR system module tube. For additional information, refer to Engine Emission Control Service and Repair.

7. Release the clamp and disconnect the brake booster vacuum hose from the TB spacer.

8. Disconnect the Evaporative Emission (EVAP) vapor tube-to-TB spacer quick connect coupling. For additional information, refer to Fuel System - General Information Service and Repair.

9. Disconnect the crankcase ventilation tube-to-TB spacer quick connect coupling. For additional information, refer to Fuel System - General Information Service and Repair.

10. Disconnect the intake manifold vacuum hose from the TB spacer.

11. If equipped, release the wire harness retainer from the crash bracket.

12. Remove the 2 bolts and the crash bracket.
- To install, tighten to 25 Nm (18 lb-ft).

13. Disconnect the 8 fuel injector electrical connectors.

14. Disconnect the fuel rail pressure and temperature sensor vacuum hose and electrical connector.

15. Disconnect the EGR module vacuum and electrical connectors.

16. Remove the 2 bolts and the intake manifold shield.
- To install, tighten to 10 Nm (89 lb-in).

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

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

19. NOTICE: O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals, and may cause the fuel system to leak.

NOTICE: Do not reuse O-ring seals. The removal and installation process may damage the used O-ring seals, and may cause the fuel system to leak.

Remove the fuel injectors and O-ring seals.

- Discard the O-ring seals.

20. 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. Description and Operation

To install, reverse the removal procedure. If equipped with a fire suppression system, repower the system.
- Install new upper and lower fuel injector O-ring seals and lubricate with clean engine oil prior to installation.