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 to prevent dirt and other contaminants from entering the fuel passages. Cap the fittings and plug the holes 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 connections.
3. Disconnect the fuel feed (1) and the return pipes (2) from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .



4. Remove the vacuum line from the fuel pressure regulator.
5. Remove the wiring harness from the fuel rail.
6. Remove the EVAP purge solenoid from the EVAP purge solenoid bracket.
7. Remove the spark plug wires from the upper intake manifold and reposition the spark plug wires.



8. Disconnect the fuel injector electrical connectors.



9. Remove the fuel rail nuts.
10. 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. The O-rings must be replaced on all components that are serviced.
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 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 nuts.

Tighten
Tighten the nuts to 10 N·m (89 lb in).




6. Connect the fuel injector electrical connectors.
7. Install the spark plug wires to the upper intake manifold.
8. Install the EVAP purge solenoid to the EVAP purge solenoid bracket.
9. Install the wiring harness to the fuel rail.



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



11. Install the vacuum line to the fuel pressure regulator.
12. Tighten the fuel fill cap.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
14. Inspect for leaks.

14.1.

Turn ON the ignition for 2 seconds.

14.2.

Turn OFF the ignition for 10 seconds.

14.3.

Turn ON the ignition.

14.4.

Inspect for fuel leaks.

15. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.