Removal Procedure
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: 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.
An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.
- Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service.
- Remove the upper intake manifold. Refer to
Upper Intake Manifold Replacement .
- Disconnect the fuel injector wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
- Disconnect the fuel injector wiring harness electrical connector from the camshaft position (CMP) sensor.
- Remove the fuel injector wiring harness electrical connector bracket bolt from the intake manifold.
- Remove the fuel rail bolts.
- Remove the fuel rail (1).
- Remove the fuel injector O-ring seal from the spray tip end of each injector, if the fuel rail was removed for other purposes.
- If replacing the fuel rail proceed to the disassembly procedure, otherwise proceed to the Installation Procedure.
Disassembly Procedure
- Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
- Remove the fuel injector wiring harness retainers from the fuel rail.
- Remove the fuel injector wiring harness.
- Remove the fuel injector retainers (1).
- Remove the fuel injectors (3).
- Remove the fuel injector upper (2) and lower (4) O-ring seals.
Assembly Procedure
- Lubricate the NEW injector O-ring seals with clean engine oil.
- Install the NEW fuel injector upper (2) and lower (4) O-ring seals.
- Install the fuel injectors (3).
- Instal the fuel injector retainers (1).
- Position the fuel injector wiring harness.
- Install the fuel injector wiring harness retainers to the fuel rail.
- Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
Installation Procedure
Notice:
• | Use care when servicing the fuel system components, especially
the fuel injector electrical connectors, the fuel injector tips, and
the injector O-rings. Plug the inlet and the outlet ports of the fuel rail
in order to prevent contamination. |
• | Do not use compressed air to clean the fuel rail assembly as this
may damage the fuel rail components. |
• | Do not immerse the fuel rail assembly in a solvent bath in order
to prevent damage to the fuel rail assembly. |
- Install NEW fuel injector O-ring seals onto the spray tip end of each injector, if the fuel rail was removed for other purposes.
- Install the fuel rail (1).
Notice: Refer to Fastener Notice in the Preface section.
- Install the fuel rail bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Align the bracket pin to the hole in the lower intake manifold.
- Install the fuel injector wiring harness electrical connector bracket bolt to the intake manifold.
Tighten
Tighten the bolt to 14 N·m (10 lb ft).
- Connect the fuel injector wiring harness electrical connector to the CMP sensor.
- Connect the fuel injector wiring harness electrical connector to the ECT sensor.
- Install the upper intake manifold. Refer to
Upper Intake Manifold Replacement .
- Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service .
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection .
- Inspect for leaks.
11.1. | Turn ON the ignition, with the engine OFF for 10 seconds. |
11.2. | Turn OFF the ignition for 10 seconds. |
11.3. | Turn ON the ignition for 10 seconds. |
11.4. | Inspect for fuel leaks. |
Removal Procedure
Warning: 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.
Caution: 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.
An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.
- Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service.
- Remove the upper intake manifold. Refer to
Upper Intake Manifold Replacement.
- Disconnect the fuel injector wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
- Disconnect the fuel injector wiring harness electrical connector from the camshaft position (CMP) sensor.
- Remove the fuel injector wiring harness electrical connector bracket bolt from the intake manifold.
- Remove the fuel rail bolts.
- Remove the fuel rail (1).
- Remove the fuel injector O-ring seal from the spray tip end of each injector, if the fuel rail was removed for other purposes.
- If replacing the fuel rail proceed to the disassembly procedure, otherwise proceed to the Installation Procedure.
Disassembly Procedure
- Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
- Remove the fuel injector wiring harness retainers from the fuel rail.
- Remove the fuel injector wiring harness.
- Remove the fuel injector retainers (1).
- Remove the fuel injectors (3).
- Remove the fuel injector upper (2) and lower (4) O-ring seals.
Assembly Procedure
- Lubricate the NEW injector O-ring seals with clean engine oil.
- Install the NEW fuel injector upper (2) and lower (4) O-ring seals.
- Install the fuel injectors (3).
- Instal the fuel injector retainers (1).
- Position the fuel injector wiring harness.
- Install the fuel injector wiring harness retainers to the fuel rail.
- Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
Installation Procedure
Caution:
• | Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination. |
• | Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components. |
• | Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly. |
- Install NEW fuel injector O-ring seals onto the spray tip end of each injector, if the fuel rail was removed for other purposes.
- Install the fuel rail (1).
Caution: Refer to Fastener Caution in the Preface section.
- Install the fuel rail bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
- Align the bracket pin to the hole in the lower intake manifold.
- Install the fuel injector wiring harness electrical connector bracket bolt to the intake manifold.
Tighten
Tighten the bolt to 14 N·m (10 lb ft).
- Connect the fuel injector wiring harness electrical connector to the CMP sensor.
- Connect the fuel injector wiring harness electrical connector to the ECT sensor.
- Install the upper intake manifold. Refer to
Upper Intake Manifold Replacement.
- Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Inspect for leaks.
11.1. | Turn ON the ignition, with the engine OFF for 10 seconds. |
11.2. | Turn OFF the ignition for 10 seconds. |
11.3. | Turn ON the ignition for 10 seconds. |
11.4. | Inspect for fuel leaks. |