Fuel Injection Fuel Rail Assembly Replacement VIN K
Removal Procedure
Tools Required
J 43013 Fuel Injector
Removal Tool
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, take precautions in order 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.
- Relieve the fuel pressure
from the fuel system. Refer to
Fuel Pressure Relief
- Clean the fuel rail assembly and the connections.
- Disconnect the fuel feed (1) and return pipes (2)
from the fuel rail tubes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Disconnect the vacuum line from the fuel pressure regulator.
- Remove the ignition coil wires.
- Disconnect the (6)
injector electrical connectors.
- Remove the fuel rail hold-down
bolts.
- Carefully raise the injectors, using the J 43013
fuel injector removal tool.
- Remove the fuel rail with equal force on both sides of the fuel
rail.
Installation 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:
• | 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. |
- Replace the O-rings on
all of the components that you service.
- Lightly oil the fuel injector O-rings with clean motor oil.
- Place the fuel rail assembly on the intake manifold.
- Seat the fuel injectors manually.
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.
- Install the fuel
rail hold down bolts.
Tighten
Torque the fuel rail hold-down bolts to 10 N·m (7 lb ft).
- Connect the (6)
fuel injector electrical connectors.
- Connect the fuel feed (1)
and the return (2) pipes to the fuel rail tubes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the vacuum line to the fuel pressure regulator.
- Install the ignition coil wires.
- Tighten the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Inspect for leaks.
12.1. | Turn the ignition switch ON for 2 seconds. |
12.2. | Turn the ignition switch OFF for 10 seconds. |
12.3. | Turn the ignition switch ON. |
12.4. | Check for fuel leaks. |
- Install the fuel injection sight shield. Refer to
Fuel Injector Sight Shield Replacement
in Engine Mechanical.
Fuel Injection Fuel Rail Assembly Replacement VIN 1
Removal 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. |
Important: When servicing the fuel rail assembly, take precautions in order 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.
- Relieve the fuel pressure from the fuel system. Refer to
Fuel Pressure Relief
.
- Clean the fuel rail assembly and the connections.
- Remove the fuel feed (2)
and return pipes (1) from the fuel rail tubes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Disconnect the vacuum line from the fuel pressure regulator.
- Remove the ignition coil wires from the coil and the retainer
clips on top of super charger.
- Remove the generator and the rear generator mounting bracket.
Refer to
Generator Replacement
in Engine Electrical.
- Remove the bypass valve actuator. Refer to
Supercharger Bypass Valve Actuator Replacement
.
- Disconnect the fuel injector
electrical connectors.
- Remove the fuel injector
electrical harness clips that hold the harness to the front of the fuel rail.
- Remove the fuel rail hold-down
bolts (4).
- Remove the fuel rail hold-down stud (1).
- Remove the fuel rail with equal force on both sides of the fuel
rail.
Installation 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:
• | 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. |
- Replace the O-rings
on all of the components that you service.
- Lightly oil the fuel injector O-rings with clean motor oil.
- Place the fuel rail assembly on the intake manifold.
- Seat the fuel injectors manually.
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.
- Install the fuel
rail hold-down bolts (4).
Tighten
Tighten the fuel rail hold-down bolts to 10 N·m (7 lb ft).
- Install the fuel rail hold-down stud (1).
Tighten
Tighten the fuel rail hold-down stud to 25 N·m (18 lb ft).
- Install the bypass valve actuator. Refer to
Supercharger Bypass Valve Actuator Replacement
.
- Install the rear generator mounting bracket and the generator.
Refer to
Generator Replacement
in
Engine Electrical.
- Connect the fuel injector
electrical harness clips holding the harness to the front of the fuel rail.
- Connect the fuel injector
electrical connectors.
- Install the ignition coil wires to the coil and the retainer clips
on top of the super charger.
- Connect the vacuum line to the fuel pressure regulator.
- Connect the fuel feed (2)
and the return pipes (1) to the fuel rail tubes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Tighten the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Inspect for leaks.
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. |
- Install the fuel injection sight shield. Refer to
Fuel Injector Sight Shield Replacement
in Engine Mechanical.