Fuel Injection Fuel Rail Assembly Replacement Without EGR

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .



4. Remove the vacuum hose at the fuel pressure regulator.



5. Remove the Camshaft Position sensor electrical connector.
6. Remove the fuel injector electrical connector retaining clips.



7. Remove the injector electrical connectors (1).
8. Remove the fuel inlet pipe at the fuel rail. (Use a backup wrench on the fuel rail inlet fitting to prevent it from turning).
9. Remove the fuel pipe retainer clip nut (if so equipped).



10. Remove the fuel pipe retainer clip bolt.



11. Remove the fuel rail attaching bolts (1).



12. Lift the fuel rail assembly (1) from the cylinder head.



13. Loosen the fuel return pipe retaining bracket attaching screw (3). (Rotate the retaining bracket (4) to allow fuel pipe to be removed).
14. Remove the fuel return pipe (2) from the fuel pressure regulator (1).
15. Remove the inlet and the return pipe assemblies. Discard O-ring (5).
16. Remove the fuel rail assembly.

1. Apply a few drops of clean engine oil to the male end of the fuel pipes before installing the fuel rail assembly.

Important: Whenever there is not enough thread-locking material on the threads of the fuel outlet pipe bracket screw, apply Loctite® 262 to insure proper locking.

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.

2. Install the fuel return pipe (2) into the fuel pressure regulator (1). (Align bracket (4) to retain return pipe).

Tighten
Tighten the return pipe bracket screw (3) to 6.0 N·m (53 lb in).

3. Install the fuel rail inlet fitting to the fuel rail assembly.

Important: Use a backup wrench on the fuel rail inlet fitting to prevent it from turning.

Tighten
Tighten fuel rail inlet fitting to 30 N·m (22 lb ft)

4. Install the fuel pipe retainer clip nut. (If so equipped)

Tighten
Tighten the fuel pipe retainer clip nut to 12 N·m(106 lb in).




5. Install the fuel pipe retainer clip bolt.

Tighten
Tighten the fuel pipe retainer clip bolt to 12 N·m(106 lb in).





Important: Lubricate fuel injectors O-rings with clean engine oil before installation.

6. Install the fuel rail assembly (1) into the cylinder head.



7. Install the fuel rail assembly attaching bolts (1).

Tighten
Tighten fuel rail attaching bolts to 26 N·m (19 lb ft).




8. Install the fuel injector electrical connectors (1).
9. Install the fuel injector electrical connector retaining clips.



10. Install the Camshaft Position sensor electrical connector.



11. Install the vacuum hose to the fuel pressure regulator.
12. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
13. Connect the negative battery cable.
14. Inspect for fuel leaks through the following steps:

14.1.

Turn the ignition switch to the ON position for two seconds.

14.2.

Turn the ignition switch to the OFF position for ten seconds.

14.3.

Turn the ignition switch to the ON position.

14.4.

Check for fuel leaks.