Fuel Rail: Service and Repair

REMOVAL
1. Drain coolant and disconnect radiator upper hose from thermostat housing.
2. Release fuel system pressure. Refer to Fuel System Pressure Release Procedure.
Service and Repair

3. Remove intake manifold plenum.

Fuel Supply And Return Tubes:

4. Using Tool 6751, disconnect the fuel supply and return tubes from the fuel rail.
5. If the injector connectors are not tagged with their cylinder number, tag them to identify the correct cylinder.
6. Remove electrical connector from injectors.

Injector Electrical Connectors:

7. Remove the vacuum tube from the fuel pressure regulator.

Fuel Injector Clamp:

8. Remove mounting bolts on both sides of fuel rail.
9. Lift fuel rail off of intake manifold plenum. Cover fuel injector openings in intake manifold plenum.

INSTALLATION
Use a new gasket when installing the rail.
1. Lightly lubricate the fuel injector O-rings with a couple drops of clean engine oil.
2. Position fuel rail over openings in intake manifold plenum. Start injectors into openings and push rail into place. Tighten fuel rail mounting bolts to 11 Nm (100 in. lbs.) torque.
3. Using Tool 6751, connect fuel supply and return tubes to fuel rail at rear of engine. Ensure quick connect fittings are fully seated to fuel rail.
4. Attach electrical connectors to fuel injectors.
5. Connect vacuum supply tube to fuel pressure regulator.
6. Install intake manifold plenum.
7. Install radiator upper hose.