Fuel Rail: Service and Repair

WARNING: The fuel system is under constant pressure of approximately 55 psi, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component.

REMOVAL

1. Release fuel system pressure. Service and Repair
2. Disconnect negative battery cable.
3. Place shop towel under hoses to catch fuel when hoses are disconnected.

Quick Connect Fuel Fittings:

4. Disconnect the Quick-Connect fittings from the chassis fuel tubes.
5. Disconnect vacuum hose from pressure regulator.
6. Disconnect fuel injector wiring harness from the main engine harness.

NOTE: Do not remove injectors from rail until entire assembly has been removed from vehicle.

Fig. 1 Fuel Rail Mounting Bolts:

7. Move oil separator bracket out of the way, and remove fuel rail support bracket screws.
8. Remove the fuel rail and injector assembly by pulling the rail so that the injectors come straight out of their ports. Be careful not to damage O-rings after removing fuel rail.
9. Inspect injector O-rings upon removal and discard any that appear damaged or worn.
10. Cover fuel injector ports while injectors are removed.

Fuel Injector Ports:

BEFORE INSTALLING FUEL RAIL

1. Seat all injectors in receiver cups and install lock rings.
2. Clean injector ports if necessary.
3. Connect injector wiring connectors and secure with wire clips.
4. Lube injector O-rings with clean 30 weight motor oil.

INSTALLATION

NOTE: Make sure oil separator bracket is on top of fuel rail bracket.

1. Install injectors in ports and install mounting bolts, tighten bolts evenly, making sure all injectors are not binding as they enter ports.
2. Once all injectors are seated, tighten mounting bolts to 200 in-lbs (22.5 Nm).
3. Connect vacuum hose to pressure regulator.
4. Connect injector harness to the main engine harness.
5. Lubricate chassis fuel tube ends with clean engine oil and connect hoses to tubes, (pull back to make sure they are securely attached).

NOTE: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless the test is stopped or the ignition switch is turned to the OFF position.

6. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto Shutdown (ASD) Relay", to activate fuel pump and pressurize system.
7. Check for leaks.