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For 1990-2009 cars only

Fuel Injection Fuel Rail Assembly Replacement VIN K

Removal Procedure

Tools Required

J 34730 Fuel Pressure Gauge


    Object Number: 180378  Size: SH

    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. Object Number: 205473  Size: SH
  3. Clean the fuel rail assembly and connections.
  4. Remove the fuel feed (2) and return (1) pipes from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .

  5. Object Number: 155470  Size: SH
  6. Remove the vacuum hose from the fuel pressure regulator.

  7. Object Number: 180061  Size: SH
  8. Remove the vacuum hose from the throttle body.

  9. Object Number: 211483  Size: SH
  10. Remove the spark plug wires from the ignition coils.

  11. Object Number: 198402  Size: SH
  12. Remove the fuel injector electrical connectors from the fuel injectors.

  13. Object Number: 12271  Size: SH
  14. Remove the fuel rail hold-down bolts.
  15. 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.


    Object Number: 12277  Size: SH
  1. The O-rings must be replaced on all components that are replaced.
  2. Lightly oil the fuel injector (4) O-rings with clean motor oil.

  3. Object Number: 12271  Size: SH
  4. Place the fuel rail assembly on the intake manifold.
  5. Seat the fuel injectors by HAND.
  6. 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.

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


    Object Number: 198402  Size: SH
  9. Install the fuel injector electrical connectors to the fuel injectors.

  10. Object Number: 205473  Size: SH
  11. Install the fuel feed (2) and return (1) pipes to the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .

  12. Object Number: 155470  Size: SH
  13. Install the vacuum hose to the fuel pressure regulator.

  14. Object Number: 180061  Size: SH
  15. Install the vacuum hose to the throttle body.

  16. Object Number: 211483  Size: SH
  17. Install the spark plug wires to the ignition coils.
  18. Install and tighten the fuel tank filler cap.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  20. 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 leaks.

    Object Number: 48328  Size: SH
  21. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Fuel Injection Fuel Rail Assembly Replacement VIN 1

Removal Procedure

Tools Required

    •  J 34730 Fuel Pressure Gauge
    • J 37088-A Fuel Line Quick-Connect Tools

    Object Number: 180378  Size: SH

    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. Object Number: 185558  Size: SH
  3. Clean the fuel rail assembly and connections.

  4. Object Number: 21197  Size: SH
  5. Remove the fuel feed (2) and return pipes (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  6. Remove the vacuum hose from the fuel pressure regulator.

  7. Object Number: 180061  Size: SH
  8. Remove the vacuum hose from the throttle body.

  9. Object Number: 211486  Size: SH
  10. Remove the ignition coil wires from the coil and retainer clips on top of super charger.

  11. Object Number: 198404  Size: SH
  12. Remove the generator and rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.
  13. Remove the fuel injector electrical connectors from the fuel injectors.

  14. Object Number: 207599  Size: SH
  15. Remove the injector electrical harness clips holding the harness to front of fuel rail.

  16. Object Number: 66405  Size: SH
  17. Remove the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
  18. Remove the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .

  19. Object Number: 12256  Size: SH
  20. Remove the fuel rail hold-down bolts from the fuel rail.
  21. 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.

  22. 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.


    Object Number: 12275  Size: SH
  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. Object Number: 12256  Size: SH
  4. Place the fuel rail assembly on the Supercharger.
  5. Seat the fuel injectors by HAND.
  6. 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.

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

  9. install the fuel rail hold down stud.
  10. Tighten
    Tighten the fuel rail hold-down stud to 25 N·m (18 lb ft).


    Object Number: 66405  Size: SH
  11. Install the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .
  12. Install the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
  13. Install the generator and rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.

  14. Object Number: 207599  Size: SH
  15. Install the fuel injector electrical harness clips holding harness to front of fuel rail.

  16. Object Number: 198404  Size: SH
  17. Install the fuel injector electrical connectors to the fuel injectors.

  18. Object Number: 211486  Size: SH
  19. Install the ignition coil wires to coil and retainer clips on top of supercharger.

  20. Object Number: 207599  Size: SH
  21. Install the vacuum hose to the fuel pressure regulator.

  22. Object Number: 180061  Size: SH
  23. Install the vacuum hose to throttle body.

  24. Object Number: 21197  Size: SH
  25. Install the fuel feed (2) and return (1) pipes to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  26. Install and tighten the fuel tank filler cap.
  27. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  28. 17.1. Turn the ignition switch On for 2 seconds.
    17.2. Turn the ignition switch Off position for 10 seconds.
    17.3. Turn the ignition switch On.
    17.4. Check for fuel leaks.

    Object Number: 49593  Size: SH
  29. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.
  30. Tighten
    Tighten the nut to 2 N·m (18 lb in).