Fuel rail and injectors — removal and installation
Warning: Gasoline is extremely flammable, so take extra precautions when you work on any part of the fuel system. See Fuel system warnings in Fuel and exhaust systems.
Removal
1. Relieve the fuel pressure (see Fuel pressure relief procedure).
2. Disconnect the cable from the negative battery terminal (see Engine electrical systems).
3. Remove the engine cover.
4. Remove the air filter housing (see Air filter housing — removal and installation).
5. Detach the fuel hose bracket near the throttle body.
6. Free the wiring harness from its clamps, then disconnect the electrical connectors from the fuel rail and injectors (see illustration).
i. 6 Disconnect the harness clamps from the intake manifold
7. Disconnect the fuel line from the fuel rail (see Fuel lines and fittings – general information and disconnection).
8. Remove the fuel rail mounting bolts (see illustration).
i. 8 Disconnect the fuel injector connectors (A) and remove the fuel rail mounting bolts (B)
9. Remove the fuel rail with the fuel injectors attached.
Note: There are two spacers that mount between the fuel rail and the cylinder head.
10. Remove the fuel injector(s) from the fuel rail by firmly pulling out of the fuel rail.
11. If you intend to re-use the same injectors, replace the grommets and 0-rings (see illustration).
i. 11 Be sure to install new 0-rings on the injectors and the fuel pulsation damper
Installation
12. Installation of the fuel injectors is the reverse of removal.
13. Apply a light coating of fuel to the injector 0-rings before installation into the fuel rail AND into the cylinder head.
14. Ensure that the fuel injectors rotate freely once installed into the cylinder head with the fuel rail.
15. Tighten the fuel rail mounting bolts to the torque listed in this Chapter’s Specifications.
16. Use a scan tool to activate the fuel pump and check for leaks. If a scan tool is not available, turn the ignition to On and verify there are no fuel leaks. If no leaks are present, start and run the engine and check for leaks again.