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 Pipe:

3. Disconnect the vacuum sensing hose from the Fuel Pressure Regulator. Disconnect electrical connectors from injectors.
4. Disconnect the fuel return hose and PCV hoses.
5. Remove the two mounting bolts and remove the Fuel Pressure Regulator.

Removing Fuel Pressure Regulator:

6. Disconnect the vacuum hoses and remove the EGR vacuum modulator.
7. Disconnect the fuel inlet pipe.

Disconnecting Fuel Inlet Hose From Fuel Rail:

8. Remove the two Fuel Rail mounting bolts.

Removing Fuel Rail:

9. 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.

10. Remove the four insulators and two spacers from the cylinder head.
11. 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.

Fuel Injector Insulators:

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.

Installing Fuel Rail With Injectors:

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

Correct Installation Of Fuel Injector In 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 Pressure Regulator using a new O-ring. Torque mounting bolts to 6.83 ft.lbs. (9.3 N-m).

Installing Fuel Pressure Regulator:

11. Connect the fuel return hose.
12. Connect injector electrical connectors.
13. Install EGR vacuum modulator and vacuum hoses.
14. Connect PCV hoses.
15. Connect vacuum sensing hose to the Fuel Pressure Regulator.
16. Connect cold start injector fuel delivery pipe with two new gaskets. Torque the union bolt to 13 ft.lbs. (18 N-m).
17. Reconnect negative battery cable.
18. Start engine and check for fuel leaks.