Fuel Rail: Service and Repair

REMOVAL:

1. Disconnect the negative battery cable.
2. Disconnect the cold start injector fuel pipe.

Removing Cold Start Injector Fuel Inlet Line:

3. Disconnect the vacuum sensing hose from the Fuel Pressure Regulator. Disconnect electrical connectors from injectors.
4. Disconnect the fuel return hose from the FPR.
5. Disconnect the fuel inlet pipe.

Disconnecting The Fuel Inlet Line From The Fuel Rail:

6. Remove the two Fuel Rail mounting bolts.

Removing The Fuel Rail:

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

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

8. Remove the four insulators and two spacers from the cylinder head.
9. When the Fuel Rail is safely over a workbench, pull the injectors from the Fuel Rail.

INSTALLATION:

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

Fuel Injector Grommet And 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 Rail until fully seated. Carefully check proper alignment to prevent fuel leaks.

Installing Fuel Injector In Fuel Rail:

4. Place four new insulators and two spacers in position on the cylinder head.

FI Insulator And FR Spacer Locations On Cylinder Head:

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

Checking For Proper Rotation Of The Fuel Injectors:

7. If the injectors do not rotate smoothly, recheck the O-rings for correct installation.

Correct Installation Of Fuel Injectors Into Fuel Rail:

8. Position injector connector sockets facing up.
9. Torque the two mounting bolts to 11 ft.lbs. (15 N-m).
10. Install the fuel inlet hose with two new gaskets. Torque the union bolt to 22 ft.lbs. (29 N-m).
11. Connect the fuel return hose to the FPR.
12. Connect injector electrical connectors.
13. Connect vacuum sensing hose to the Fuel Pressure Regulator.
14. Connect cold start injector fuel delivery pipe with two new gaskets. Torque the union bolt to 13 ft.lbs. (18 N-m).
15. Reconnect negative battery cable.
16. Start engine and check for fuel leaks.