Fuel Injection Fuel Rail Assembly Replacement VIN K

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

Important: Always maintain cleanliness when servicing fuel system components.

1. Remove the injector sight shield.



2. Bleed the fuel pressure from the fuel system. Refer to Fuel Pressure Relief
3. Clean the fuel rail assembly and connections.
4. Remove the fuel feed, (1) and return pipes (2) from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



5. Remove the vacuum line from the fuel pressure regulator.
6. Remove the ignition coil wires.



7. Remove the (6) injector electrical connectors.



8. Remove the fuel rail hold-down bolts.
9. Remove the fuel rail with equal force on both sides of the fuel rail.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

Notice: 

1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the fuel rail hold down bolts.

Tighten
Torque the fuel rail hold-down bolts to 10 N·m (7 lb ft).




6. Install the (6) fuel injector electrical connectors.



7. Install the fuel feed (1) and return (2) pipes to the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



8. Install the vacuum line to the fuel pressure regulator.
9. Install the ignition coil wires.
10. Inspect for leaks.

10.1.

Turn the ignition switch ON for 2 seconds.

10.2.

Turn the ignition switch OFF for 10 seconds.

10.3.

Turn the ignition switch ON.

10.4.

Visually inspect the fuel system for fuel leaks.




11. Install the injector sight shield.

Fuel Injection Fuel Rail Assembly Replacement VIN 1

Notice: 

Important: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

1. Remove the injector sight shield.
2. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief .
3. Clean the fuel rail assembly and connections.



4. Remove the fuel feed, (2) and return pipes (1) from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



5. Remove the vacuum line from the fuel pressure regulator.
6. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
7. Remove the generator and rear generator mounting bracket.
8. Remove the bypass valve actuator. Refer to Supercharger Bypass Valve Actuator Replacement .



9. Remove the (6) fuel injector electrical connectors.



10. Remove the fuel injector electrical harness clips holding harness to front of fuel rail.



11. Remove the fuel rail hold-down bolts (4).
12. Remove the fuel rail hold down stud (1).
13. Remove the fuel rail with equal force on both sides of the fuel rail.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

Notice: 

1. The O-rings must be replaced on all components that are serviced.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. Seat the fuel injectors by HAND.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the fuel rail hold-down bolts (4).

Tighten
Tighten the fuel rail hold-down bolts to 10 N·m (7 lb ft).

6. Install the fuel rail hold down stud (1).

Tighten
Tighten the fuel rail hold-down stud to 25 N·m (18 lb ft).

7. Install the bypass valve actuator. Refer to Supercharger Bypass Valve Actuator Replacement .
8. Install the rear generator mounting bracket and generator. Refer to following procedures in Engine Electrical:

•	Generator Bracket Replacement

•	Generator Brace Replacement

•	Generator Replacement




9. Install the fuel injector electrical harness clips holding harness to front of fuel rail.



10. Install the (6) fuel injector electrical connectors.
11. Install the ignition coil wires to coil and retainer clips on top of super charger.



12. Install the vacuum line to the fuel pressure regulator.



13. Install the fuel feed, (2) and return pipes (1) to the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



14. Install the fuel injection sight shield.