Fuel Rail: Service and Repair
Removal ProcedureTools Required
^ Injector Remover J 41081 Injector Remover J37088 Fuel Line Quick Connect Separator
CAUTION: Use care in removing the fuel rail assembly to prevent damage to the injector electrical connector terminals and the injector spray tips. When removed, support the rail to avoid damaging its components.
NOTE: Prevent dirt and other contaminants from entering open pipes and passages. Fittings should be capped, and holes plugged, during servicing.
1. Remove the rear seat cushion.
2. Remove the negative battery cable
3. Relieve fuel system pressure. Refer to Fuel Pressure Release.
Air Inlet Duct:
4. Remove the air intake duct.
EGR Valve Water Pump Crossover Pipe:
5. Remove the EGR pipe at throttle body spacer.
6. Remove the brake booster vacuum hose at intake manifold vacuum fitting.
7. Remove the front bank spark plug wires.
MAF Sensor:
8. Remove the MAP sensor electrical connector.
Injector Components:
9. Remove the injector electrical connectors. Lay harness aside.
10. Remove the fuel rail ground wire (7) at rear cylinder head.
11. Remove the fuel pressure regulator (1).
Crankcase Ventilation Pipe:
12. Remove the crankcase ventilation vacuum lines.
13. Remove the quick-connect fittings at the fuel rail.
14. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within fitting.
Caution: Wear safety glasses when using compressed air because flying dirt particles may cause eye injury.
15. Blow dirt out of fining, using compressed air.
16. Squeeze plastic retainer release tabs
Caution: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the 0-ring sealing surface.
17. Pull connection apart.
Throttle Body:
18. Remove the throttle body mount bolts.
19. Remove the throttle body.
20. Remove the throttle body spacer (3).
21. Remove the throttle body 0-ring seal.
Injector Components:
22. Release the locking tabs (8) on fuel rail by pushing toward center of intake manifold and pry each injector out of intake manifold using J 41081.
Fuel Rail:
22. Remove the fuel rail assembly.
Disassemble Procedure
1. Remove the injector harness.
2. Remove the clips from the injectors on the fuel rail.
3. Remove the upper and lower seals from the injectors. Discard seals.
Assemble Procedure
1. Lubricate the upper and lower injector 0-rings with clean oil and install on the 0-rings unto the injectors.
2. Assemble the injectors to the fuel rail with new retainer clips
3. Assemble the injector harness.
Installation Procedure
1. Install the fuel rail with injectors to intake manifold.
2. Install throttle body spacer.
3. Install the new throttle body 0-ring seal.
4. Install the throttle body.
5. Install the throttle body mount bolts. Tighten the throttle body mount bolts to 12 Nm (106 lb in).
6. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet pipes.
7. Install the quick-connect fittings to fuel rail.
8. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
9. Once installed, pull on both sides of fitting to make sure connection is secure.
10. Install the fuel pressure regulator.
11. Install the crankcase ventilation vacuum lines.
12. Install the fuel rail ground wire at rear cylinder head.
13. Install the injector harness and injector electrical connectors.
14. Install the MAP sensor electrical connector.
15. Install the front bank spark plug wires.
16. install the brake booster vacuum hose at intake manifold vacuum fitting.
17. Install the EGR pipe at throttle body spacer. Tighten the EGR pipe bolt to 28 Nm (21 lb in).
18. Install the air intake duct.
19. Tighten fuel filler cap.
20. Install the negative battery cable.
20.1 Turn ignition switch to the On position for 2 seconds.
20.2 Turn the ignition switch OFF for 10 seconds.
20.3 Turn the ignition switch ON.
20.4 Check for fuel leaks.
21. Install the rear seat cushion.
22. Install the intake manifold top cover.