Fuel Rail: Service and Repair

REMOVAL:

1. Disconnect the negative battery cable.
2. Remove air intake connector.
3. Disconnect accelerator cable and throttle cable, if A/T model.
4. Disconnect the cold start injector fuel pipe.

Disconnecting Cold Start Injector Fuel Pipe:

5. Disconnect the vacuum sensing hose from the Fuel Pressure Regulator. Disconnect electrical connectors from injectors.
6. Remove Dashpot/Link bracket.

Removing Dashpot/Link Bracket:

7. Disconnect fuel return hose and PCV hoses.
8. Remove the fuel pressure pulsation damper and disconnect the fuel inlet pipe.

Removing Fuel Pressure Pulsation Damper:

9. Remove the two Fuel Rail mounting bolts.

Removing Fuel Rail:

10. 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.

11. Remove the four insulators and two spacers from the cylinder head.
12. 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.

Correct Installation Of Injector In Fuel Rail:

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

Installing Insulators And Spacers 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 Fuel Injectors For Binding O-Rings:

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

Proper Fuel Injector Component Installation:

8. Position injector connector sockets facing up.
9. Torque the two mounting bolts to 14 ft.lbs. (19 N-m).
10. Install fuel pressure pulsation damper with new gaskets and fuel inlet hose. Torque to 22 ft.lbs. (29 N-m).
11. Connect the fuel return and PCV hoses.
12. Connect injector electrical connectors.
13. Install Dashpot/Link bracket.
14. Connect vacuum sensing hose to the Fuel Pressure Regulator.
15. Connect cold start injector fuel delivery pipe with two new gaskets. Torque the union bolt to 14 ft.lbs. (20 N-m).
16. Reconnect the throttle cable (A/T only) and the accelerator cable. Refer to ADJUSTMENT PROCEDURES and adjust cable.
17. Reconnect negative battery cable.
18. Start engine and check for fuel leaks.