Fuel Rail: Service and Repair

REMOVAL:

1. Disconnect the negative battery cable.
2. Drain the engine coolant from the radiator.
3. On A/T models, disconnect the throttle cable from the throttle body and bracket. Disconnect the accelerator cable and bracket from the throttle body and air intake chamber.
4. Remove the air cleaner cap, airflow meter and air cleaner hose.

Air Cleaner:

5. Disconnect hoses and connectors.
a. PCV hoses
b. Vacuum sensing hose to Fuel Pressure Regulator
c. Water bypass hose
d. Emission control vacuum hoses
e. Idle Speed Control (ISC) connector
f. TPS connector
g. EGR gas temperature sensor connector (Ca. only)

Throttle Body Vacuum Hoses:

6. Remove the three bolts and the No. 1 engine RH mounting stay.
7. Disconnect cold start injector connector. Disconnect cold start injector fuel tube.
8. Disconnect hoses and parts.
a. Brake booster vacuum hose
b. Power steering vacuum and air hoses
c. Cruise control vacuum hose
d. Ground strap connector
e. Wire harness clamp
10. Disconnect the EGR pipe.
11. Remove No. 1 engine hanger and air intake chamber stay.

No. 1 Engine Hanger And Air Intake Stay:

12. Remove intake air chamber.

Removing Intake Air Plenum:

13. Disconnect cold start injector, water temperature sensor and the six injector connectors.
14. Disconnect wire harness from LH delivery pipe.
15. Disconnect fuel inlet and two fuel return hoses.
16. Remove the No. 2 fuel pipe and four gaskets from the Fuel Rails.

Removing No. 2 Fuel Pipe:

17. Remove two mounting bolts from the LH Fuel Rail. Remove the Fuel Rail with the injectors.

CAUTION: Be careful that the injectors do not drop from the Fuel Rail. Damage to the injector tip could result.

Fuel Rails With Fuel Pressure Pulsation Damper:

18. Remove three mounting bolts from the RH Fuel Rail. Remove the Fuel Rail with the injectors.
19. After the Fuel Rails are safely over a workbench, pull the injectors from the respective Fuel Rails.
20. Remove the six insulators and the four spacers from the intake manifold.

INSTALLATION:

1. Install a new grommet and o-ring on each removed injector.

Fuel Injector O-Ring:

2. Apply a light coat of gasoline to the O-ring to ease insertion into the Fuel Rail.
3. With a twisting motion, install each injector into the Fuel Rails until fully seated. Carefully check proper alignment to prevent fuel leaks.

Correct Installation Of Fuel Injector To Fuel Rail:

4. Place six new insulators and the four spacers in position on the intake manifold.

Fuel Rail Insulators And Spacers:

5. Carefully install the RH Fuel Rail with injectors on the intake manifold.
6. Start the three mounting bolts, but do not tighten. Rotate each injector to ensure that there is no binding of the sealing parts.

Installing Fuel Rails With Fuel Injectors:

7. Carefully install the LH Fuel Rail with injectors on the intake manifold.
8. Start the two mounting bolts, but do not tighten. Rotate each injector to ensure that there is no binding of the sealing parts.
9. If the injectors do not rotate smoothly, recheck the O-rings for correct installation.
10. Position injector connector sockets facing up.
11. Torque all five mounting bolts to 9 ft.lbs. (13 N-m).
12. Install No. 2 fuel pipe with four new gaskets and torque the two union bolts to 21 ft.lbs. (29 N-m).

Installing No. 2 Fuel Pipe:

13. Connect the fuel inlet and return hoses with new gaskets.
14. Connect three wire harness clamps to LH Fuel Rail.
15. Connect cold start injector, water temperature sensor and six injector connectors.
16. Install air intake chamber and new gasket. Torque the two bolts and two nuts to 29 ft.lbs. (39 N-m).

Installing Intake Air Plenum:

17. Connect EGR pipe and torque to 58 ft.lbs. (78 N-m).
18. Connect wire harness clamp with nut.
19. Install No. 1 engine hanger and air intake chamber stay. Torque bolts to 27 ft.lbs. (37 N-m).

Installing No. 1 Engine Hanger And Air Intake Stay:

20. Connect all hoses and parts that were disconnected in step 8 of removal procedure.
21. Connect cold start injector fuel tube and electrical connector.
22. Install No. 1 engine RH mounting stay with three bolts. Torque bolts to 38 ft.lbs. (52 N-m).

Installing Engine RH Mounting Stay:

23. Connect all connectors and hoses that were disconnected in step 5 of the removal procedure.
24. Install air cleaner cap, airflow meter and air cleaner hose.
25. Connect accelerator cable and bracket to throttle body and air intake chamber. On A/T models, connect throttle cable to throttle body and bracket. Refer to ADJUSTMENT PROCEDURES for proper adjustment procedure.
26. Fill radiator with coolant.
27. Reconnect the negative battery cable.
28. Start engine and check for fuel or coolant leaks.