Fuel Injection Fuel Rail Assembly Replacement VIN K

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.

1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief
2. Clean the fuel rail assembly and the connections.
3. Disconnect the fuel feed (1) and return pipes (2) from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires.



6. Disconnect the (6) injector electrical connectors.



7. Remove the fuel rail hold-down bolts.
8. Carefully raise the injectors, using the J 43013 fuel injector removal tool.
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: 

1. Replace the O-rings on all of the components that you service.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. 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.

5. Install the fuel rail hold down bolts.

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




6. Connect the (6) fuel injector electrical connectors.



7. Connect the fuel feed (1) and the return (2) pipes to the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



8. Connect the vacuum line to the fuel pressure regulator.
9. Install the ignition coil wires.
10. Tighten the fuel fill cap.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
12. 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.

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

Fuel Injection Fuel Rail Assembly Replacement VIN 1

Notice: 

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.

1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief .
2. Clean the fuel rail assembly and the connections.



3. Remove the fuel feed (2) and return pipes (1) from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .



4. Disconnect the vacuum line from the fuel pressure regulator.
5. Remove the ignition coil wires from the coil and the retainer clips on top of super charger.
6. Remove the generator and the rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.
7. Remove the bypass valve actuator. Refer to Supercharger Bypass Valve Actuator Replacement .



8. Disconnect the fuel injector electrical connectors.



9. Remove the fuel injector electrical harness clips that hold the harness to the front of the fuel rail.



10. Remove the fuel rail hold-down bolts (4).
11. Remove the fuel rail hold-down stud (1).
12. 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: 

1. Replace the O-rings on all of the components that you service.
2. Lightly oil the fuel injector O-rings with clean motor oil.
3. Place the fuel rail assembly on the intake manifold.
4. 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.

5. Install the fuel rail hold-down bolts (4).

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

6. Install the fuel rail hold-down stud (1).

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

7. Install the bypass valve actuator. Refer to Supercharger Bypass Valve Actuator Replacement .
8. Install the rear generator mounting bracket and the generator. Refer to Generator Replacement in Engine Electrical.



9. Connect the fuel injector electrical harness clips holding the harness to the front of the fuel rail.



10. Connect the fuel injector electrical connectors.
11. Install the ignition coil wires to the coil and the retainer clips on top of the super charger.



12. Connect the vacuum line to the fuel pressure regulator.



13. Connect the fuel feed (2) and the return pipes (1) to the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .
14. Tighten the fuel fill cap.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
16. 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.

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