Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure




Caution: Refer to Relieving Fuel Pressure Caution (Technician Safety Information).
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Fuel Pressure Relief).
Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution).
2. Disconnect the negative battery cable.
3. Remove the engine cover bolts and cover.




4. Disconnect the electronic throttle control connector.
5. Disconnect the intake air temperature sensor.
6. Disconnect the camshaft position sensor.
7. Disconnect the manifold absolute pressure sensor.
8. Disconnect the fuel injector harness connectors.




9. Remove the purge solenoid valve to intake manifold hose.
10. Remove the MAP sensor vacuum hose.
11. Remove the upper intake manifold bracket bolts.
12. Remove the upper intake manifold bracket.




13. Disconnect the fuel feed line.




14. Disconnect the throttle body outlet coolant hose.

Notice:
* Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
* Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
* Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

15. Remove the fuel rail mounting bolts.





Notice:
* Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
* Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
* Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.


Important: If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.


16. Remove the fuel rail with the fuel injectors attached.
17. Remove the fuel injector retaining clips.
18. Remove the fuel injectors by pulling down and out.
19. Discard the fuel injector O-rings.


Installation Procedure





Important: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.


1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
3. Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge.
4. Make sure that the clip is parallel to the fuel injector harness connector.




5. Install the fuel rail assembly into the cylinder head.

Notice: Refer to Fastener Notice (Fastener Notice).

6. Install the fuel rail mounting bolts.

Tighten the fuel rail mounting bolts to 25 N.m (18 lb ft).

7. Connect the throttle body coolant hose.




8. Connect the fuel feed hose.




9. Install the intake manifold upper bracket with the bolts.
10. Install the MAP sensor vacuum hose.
11. Install the purge solenoid to intake manifold hose.




12. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wiring harness.
13. Connect the MAP sensor connector.
14. Connect the Camshaft position sensor.
15. Connect the intake air temperature sensor.
16. Connect the electronic throttle control connector.




17. Install the engine cover with bolts.
18. Connect the negative battery cable.
19. Perform a leak check of the fuel rail and fuel injectors.