Fuel Injection Fuel Rail Assembly Replacement VIN K

Tools Required

J 34730 Fuel Pressure Gauge

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. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief .



2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed pipes (1) and the fuel return pipes (2) from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .



4. Remove the vacuum hose from the pressure regulator.



5. Remove the vacuum hoses from the throttle body.



6. Remove the ignition coil wires from the ignition coils.



7. Remove the electrical connectors from the fuel injectors.



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: 

Important: The O-rings must be replaced on any components that are replaced.

1. Lightly oil the fuel injector O-rings with clean motor oil.
2. Place the fuel rail assembly on the intake manifold.
3. 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.

4. Install the fuel rail hold down bolts.

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




5. Install the electrical connectors to the fuel injectors.



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



7. Install the vacuum hose to the pressure regulator.



8. Install the vacuum hoses to the throttle body.



9. Install the ignition coil wires to the ignition coils.



10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.

Fuel Injection Fuel Rail Assembly Replacement VIN 1

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.




1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief .
2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed and return pipe quick-connect retainers (4).
4. Remove the fuel feed (3) and return pipes (1) from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .



5. Remove the vacuum hoses from the throttle body.



6. Remove the ignition coil wires from the ignition coil and from the retainer clips on top of the supercharger.
7. Remove the generator and the rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.



8. Remove the electrical connectors from the fuel injectors.



9. Remove the vacuum hose from the fuel pressure regulator.
10. Remove the fuel injector harness clips that retain the harness to the front of fuel rail.



11. Remove the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
12. Remove the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .



13. Remove the hold-down bolts from the fuel rail.

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.

14. Remove the fuel rail using 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 replaced.
2. Lightly oil the fuel injector (2) O-rings with clean motor oil.



3. Place the fuel rail assembly on the supercharger.
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
Tighten the bolts to 10 N·m (7 lb ft).

6. Install the fuel rail hold-down stud.

Tighten
Tighten the stud to 25 N·m (18 lb ft).




7. Install the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .
8. Install the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
9. Install the generator and the rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.



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



11. Install the electrical connectors to the fuel injectors.



12. Install the ignition coil wires to the coils and retainer clips on top of supercharger.



13. Install the vacuum hose to the fuel pressure regulator.



14. Install the vacuum hoses to the throttle body.



15. Install the fuel feed (3) and return (1) pipes to the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .
16. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

16.1.

Turn ON the ignition switch for 2 seconds.

16.2.

Turn OFF the ignition switch for 10 seconds.

16.3.

Turn ON the ignition switch.

16.4.

Check for fuel leaks.




17. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.

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