Fuel Rail: Service and Repair

REMOVAL:

1. Remove the Throttle Body from the intake plenum. Refer to THROTTLE BODY for proper procedure.
2. Remove the air cleaner assembly and the charcoal canister.
3. Remove the EGR VSV, vacuum modulator and bracket.
4. Remove the EGR valve and pipe assembly.
5. Remove the cold start injector fuel pipe and cold start injector. Refer to COLD START INJECTOR for proper procedure.
6. Remove the ISC water bypass hoses and the No.1 air tube. Disconnect electrical connectors from injectors.

Removing Water Bypass Hoses And Air Hose:

7. Disconnect the two wire clamps from the timing cover.

Removing Engine Wire Clips:

8. Disconnect the two wire clamps from the brackets on the intake manifold.

Removing Wire Clamp Brackets:

9. Using a wrench, remove the fuel inlet hose union bolt along with the two sealing gaskets.

Disconnecting Fuel Inlet Hose From Fuel Rail:

10. Disconnect the fuel hose from the fuel return pipe.

Fuel Return Hose And FPR:

11. Remove the three Fuel Rail mounting bolts.

Removing Fuel Rail:

12. Lift the Fuel Rail with the injectors from the cylinder head.

Removing Fuel Rail With Fuel Injectors:

13. Remove the four insulators and three spacers from the cylinder head.
14. Remove the fuel inlet hose from the fuel rail.

Disconnecting Fuel Inlet Hose From Fuel Rail:

INSTALLATION:

1. Install fuel inlet pipe using new gaskets, on the Fuel Rail. Torque the union bolt to 22 ft.lbs. (29 N-m).
2. Torque the clamp bolt to 69 in.lbs. (7.8 N-m).
3. Install a new insulator on each injector opening.

Installing New Insulators On Injectors:

4. Place three spacers in position on the cylinder head.

Installing Spacers On Cylinder Head:

5. Install the Fuel Rail/Injector assembly with the three mounting bolts. Torque the bolts to 14 ft.lbs. (19 N-m).
6. Connect the fuel return hose to the FPR.
7. Connect the fuel inlet hose to the fuel filter. Torque the union bolt to 22 ft.lbs. (29 N-m).
8. Install engine wire clamps to the wire brackets on the intake manifold.
9. Install the two wire clips on the timing cover.
10. Connect injector connectors. Ensure that brown connectors are attached to No.1 and No.3 cylinders, while gray connectors go to No.2 and No.4 cylinders.

Proper Connection Of Injector Connectors:

11. Install the ISC water bypass hoses and the No.1 air tube.
12. Connect cold start injector and fuel delivery pipe with two new gaskets. Refer to COLD START INJECTOR for proper procedure.
13. Install the EGR valve and pipe assembly.
14. Install the EGR VSV, vacuum modulator and bracket.
15. Install the air cleaner assembly and the charcoal canister.
16. Reinstall the Throttle Body on the intake plenum. Refer to THROTTLE BODY for proper procedure.
17. Start engine and check for fuel leaks.