Fuel Rail: Service and Repair
FUEL RAIL AND FUEL INJECTORS REPLACEMENTNOTE: Use care when handling the injector, to prevent damage especially to the filter and the injector needle. Also, because the injector is an electrical component, it should not be immersed in any type of liquid solvent or cleaner, as damage may occur.
NOTE: Drain coolant from engine before proceding.
Fuel Rail Storm:
REMOVE OR DISCONNECT:
1. Negative battery cable.
2. Relieve fuel pressure.
3. Accelerator cable and cruise control from air cleaner assembly clip.
4. Intake air temperature sensor electrical connector.
5. Loosen air cleaner hose clamp on throttle body, and four clips on air cleaner cap.
6. Air cleaner hose and air cleaner cap from vehicle.
7. Two nuts and accelerator cable from bracket and throttle lever.
8. Two nuts and TV cable from bracket and throttle lever (auto trans. only).
Throttle Body Vacuum Hoses:
9. Two EGR vacuum hoses from throttle body.
10. One EVAP hose from throttle body.
11. Throttle position sensor electrical connector.
12. Idle air control valve electrical connector.
Throttle Body Removal:
13. Two bolts, two nuts and throttle body and gasket from intake manifold.
Fuel Hose Removal:
14. Two bolts and fuel feed/return hose bracket from intake manifold.
15. EGR hoses and from EGR valve and pipe (California emissions).
16. One bolt, one nut, engine hanger assembly and EGR vacuum modulator assembly from intake manifold.
EGR Components:
17. EGR temperature sensor electrical connector (California emissions).
18. Four nuts, two gaskets and EGR valve and pipe.
Fuel Pressure Regulator Vacuum Hose:
19. One vacuum hose from fuel pressure regulator.
20. Two clamps and hose from positive crankcase ventilation valve and intake manifold.
Air Intake Chamber Cover:
21. Two nuts and three screws, air intake chamber and gasket.
Fuel Injectors:
22. Fuel injector electrical connectors.
Fuel Hose Removal:
23. One bolt and fuel feed inlet hose from fuel rail.
24. One clamp and fuel return hose from fuel pressure regulator
Fuel Rail Removal:
25. Two bolts and injectors with fuel rail from vehicle.
26. four insulators from the intake manifold.
27. Four injectors from the fuel rail.
28. O-rings and grommets from each injector.
29. Two bolts and fuel pressure regulator from the fuel rail.
INSTALL OR CONNECT:
1. Fuel pressure regulator to fuel rail; secure with two bolts.
Fuel Injector O-ring Installation:
2. New O-rings and grommets to each injector.
Fuel Injector Installation:
3. Four injectors to the fuel rail; positioning the connector upward.
4. Four new insulators and two spacers in position on the intake manifold.
5. Fuel injectors with fuel rail to intake manifold; secure with two bolts. Do not tighten fully.
NOTE: Check that injector rotate smoothly. If they do not, the probable cause is incorrect installation of O-rings.
6. Tighten fuel rail to intake manifold bolts to 11 ft.lbs. (15 Nm).
7. Fuel feed inlet hose to fuel rail; secure with one clamp.
8. Fuel return hose from to pressure regulator; secure with one clamp.
9. Fuel injector electrical connectors.
10. Air intake chamber cover and new gasket to air intake chamber; secure with two nuts and three screws. Tighten to 14 ft.lbs. (19 Nm).
11. Vacuum hose to fuel pressure regulator.
12. Positive crankcase ventilation valve hose to valve and intake manifold; secure with two clamps.
13. EGR valve with new gaskets and pipe; secure with four nuts.
14. EGR temperature sensor electrical connector (California emissions).
15. Engine hanger assembly and EGR vacuum modulator; secure with one nut and bolt. Tighten to 21 ft.lbs. (28 Nm).
16. EGR hoses and to EGR valve and pipe (California emissions).
17. Fuel feed/return hose bracket to intake manifold; secure with two bolts. Tighten to 7 ft.lbs. (10 Nm).
18. Throttle body and gasket to intake manifold; secure with two bolts and two nuts. Tighten to 16 ft.lbs. (22 Nm).
19. Idle air control valve electrical connector.
20. Throttle position sensor electrical connector.
21. One EVAP vacuum hose to throttle body.
22. Two EGR vacuum hoses to throttle body.
23. TV cable to bracket and throttle lever (auto trans only); secure with two nuts.
24. Accelerator cable to bracket and throttle lever; secure with two nuts.
25. Air cleaner hose and air cleaner cap.
26. Four clips on air cleaner cap and air cleaner hose on throttle body.
27. Intake air temperature sensor electrical connector.
28. Accelerator cable and cruise control to air cleaner assembly clip.
29. Negative battery cable.