For 1990-2009 cars

## Fuel Injection Fuel Rail Assembly Replacement VIN K

### Removal Procedure

#### Tools Required

J 34730 Fuel Pressure Gauge

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. Clean the fuel rail assembly and connections.
3. Remove the fuel feed (2) and return (1) pipes from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .
4. Remove the vacuum hose from the fuel pressure regulator.
5. Remove the vacuum hose from the throttle body.
6. Remove the ignition coil wires.
7. Remove the fuel injector electrical connectors.
8. Remove the fuel rail hold-down bolts.
9. 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.

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. 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 hold down bolts.

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

6. Install the fuel injector electrical connectors to the fuel injectors.
7. Install the fuel feed (2) and return (1) pipes to the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service .
8. Install the vacuum hose to the fuel pressure regulator.
9. Install the vacuum hose to throttle body.
10. Install the ignition coil wires.
11. 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

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. Clean the fuel rail assembly and connections.
3. Remove the fuel feed (2) and return pipes (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
4. Remove the vacuum hose from the fuel pressure regulator.
5. Remove the vacuum hose from the throttle body.
6. Remove the ignition coil wires from the coil and retainer clips on top of super charger.
7. Remove the generator and rear generator mounting bracket. Refer to Generator Replacement .
8. Remove the fuel injector electrical connectors from the fuel injector.
9. Remove the injector electrical harness clips holding the harness to front of fuel rail.
10. Remove the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
11. Remove the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .
12. Remove the fuel rail hold-down bolts from the fuel rail.

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.

13. 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.

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. 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 hold-down bolts.

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

6. install the fuel rail hold down stud.

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

7. Install the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .
8. Install the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
9. Install the generator and rear generator mounting bracket. Refer to Generator Replacement .
10. Install the fuel injector electrical harness clips holding harness to front of fuel rail.
11. Install the fuel injector electrical connectors to the fuel injectors.
12. Install the ignition coil wires to coil and retainer clips on top of super charger.
13. Install the vacuum hose to the fuel pressure regulator.
14. Install the vacuum hose to throttle body.
15. Install the fuel feed (2) and return (1) pipes to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
16. Install the fuel injector sight shield.

Tighten
Tighten the fuel injector sight shield nut to 2 N·m (18 lb in).