Fuel Rail: Service and Repair

TOOLS REQUIRED
^ 309725 Fuel Gauge Pressure Adapter
^ J 43937 Fuel Pressure Adapter Lines

REMOVAL

CAUTION: Place a dry chemical (class b) fire extinguisher near work area before attempting an on-vehicle service.

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




1. Disconnect negative battery terminal.
2. Relieve fuel system pressure. (Refer to "Fuel System Pressure Relief" procedure.) Service and Repair
3. Disconnect fuel lines.




4. Remove upper plenum.
5. Disconnect fuel injector electrical harness connector.
6. Disconnect fuel injector connectors.
7. Remove fuel rail attaching bolts from intake manifold.
8. Disconnect fuel pressure regulator vacuum line.

CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.

9. Use compressed air to blow debris away from area where injectors enter intake manifold.
10. Remove fuel injector locking clips. Pry each fuel injector from intake manifold.
11. Remove fuel rail assembly.
12. Remove fuel injector assemblies from fuel rail.

IMPORTANT: Any time fuel system is opened for service, O-ring seals used with related components must be replaced.

13. Remove rust or burrs from engine fuel pipes using the following procedures.
a. Use emery cloth in order to remove rust or burrs from fuel pipes. Use a radial motion on fuel pipe end in order to prevent damage to O-ring sealing surface.
b. Use a clean shop towel to wipe male tube ends clean.
c. Inspect all connectors for dirt and burrs. Clean or replace damaged components as necessary.
14. Remove O-rings from fuel injectors.

INSTALLATION




1. Lubricate new fuel injector O-rings with clean engine oil.
2. Install new fuel injector O-rings onto fuel injectors.
3. Install new retainer clips onto fuel prior to installing fuel injector to fuel rail.
4. Install fuel injector assembly into fuel rail with fuel injectors electrical socket facing upward.

IMPORTANT: Press injector into fuel rail until it "clicks" into retainer clip.

5. Rotate injectors so that they are perpendicular to fuel rail.




6. Install fuel rail assembly to intake manifold.
7. Connect fuel pressure regulator vacuum line.
8. Install fuel rail bolts.

Torque: 8 N.m (71 in-lbs)

9. Connect fuel injector electrical connectors.
10. Connect fuel line quick connects.
11. Install intake plenum.
12. Connect negative battery cable.
13. Crank engine for a few seconds. Turn off engine if starts.
14. Inspect for fuel leaks.