Fuel Injection Fuel Rail Assembly Replacement 4.6

Tools Required

Refer to J 41081 Injector Remover, J 37088-A Fuel Line Quick-Connect Separator

Notice: 

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
2. Remove the intake air duct clamp from the air cleaner assembly.
3. Remove the intake air duct clamp from the MAF Sensor
4. Remove the EGR pipe and crankcase ventilation pipe at throttle body spacer.
5. Remove the brake booster vacuum hose at intake manifold.
6. Remove the front bank spark plug wires.
7. Remove the injector harness electrical connector.
8. Remove transaxle vent hose from clip.



9. Remove the fuel pressure regulator vacuum line.
10. Disconnect the quick-connect fittings at fuel rail.
11. Grasp both sides of fitting.



12. Remove the fuel rail ground wire (1) at rear cylinder head.



13. Twist the female connector 1/4 turn in each direction to loosen any dirt within fitting.




Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

14. Blow dirt out of fitting using compressed air.
15. Choose correct tool from J 37088-A tool set for size of fitting.



16. Insert tool into female connector, then push/pull inward to release locking tabs.




Notice: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

17. Pull connection apart.



18. Disconnect fuel pipe bracket at EGR valve.
19. Remove throttle body mount bolts.
20. Release locking tabs on fuel rail and pry each injector out of intake manifold using J 41081.
21. Remove the fuel rail assembly.

1. Remove the injector harness.
2. Remove the injector(s) (12) from the fuel rail.
3. Remove the upper (11) and lower (13) O-rings from injectors.
4. Discard the O-rings.
5. Clean the throttle body O-ring surfaces.

1. Lubricate the new upper (11) and lower (13) injector O-rings with clean engine oil and install on injectors.
2. Install the injectors to fuel rail with new retainer clip(s).

2.1.	Ensure injectors are aligned by orientating electrical connector perpendicular to crankshaft.

3. Install the injector harness.

1. Install the fuel rail with injectors to intake manifold.



2. Install the new throttle body spacer gasket (2), throttle body spacer (3), and mount bolts.

Tighten
Tighten the throttle body spacer bolts to 12 N·m (106 lb in).

3. Install the new throttle body gasket, throttle body, and bolts.

Tighten
Tighten the throttle body bolts to 12 N·m (106 lb in).




4. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet pipes.
5. Install the quick-connect fittings to fuel rail:



6. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.



7. Pull on both sides of fitting to make sure connection is secure once installed.



8. Install the fuel pressure regulator and crankcase ventilation vacuum lines.



9. Install the fuel rail ground wire (1) at rear cylinder head.
10. Install the injector harness and injector electrical connectors.
11. Install the MAP sensor electrical connector.
12. Install the front bank spark plug wires.
13. Install the brake booster vacuum hose at intake manifold vacuum fitting.



14. Install the EGR pipe at throttle body spacer.

Tighten
Tighten the EGR pipe bolt to 28 N·m (21 lb ft).




15. Install the intake air duct clamp to the MAF Sensor.
16. Install the intake air duct clamp to from the air cleaner assembly.
17. Tighten fuel filler cap.
18. Install the negative battery cable.
19. Inspect for leaks.

19.1.

Turn the ignition switch ON for 2 seconds.

19.2.

Turn the ignition switch OFF for 10 seconds.

19.3.

Turn the ignition switch ON.

19.4.

Check for fuel leaks.




20. Install the intake manifold top cover.

Tighten
Tighten the nuts to 2 N·m (18 lb in).