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Fuel Rail

Powertrain Management › Fuel Delivery and Air Induction
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartFuel Rail
ManufacturerCHY
OEM part #53031102AB
Price$274.00

Labor

Replace1.4 hr
Warranty 0.0 hrSkill B
Procedures
Fuel Rail - Installation16 steps
Fig. 1
Fig. 1
  1. If fuel injectors are to be installed.
  2. Clean out fuel injector machined bores in intake manifold.
  3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation.
  4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head.
  5. Guide each injector into cylinder head. Be careful not to tear injector O-rings.
  6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder.
  7. Install four fuel rail mounting bolts and tighten to 11 Nm (100 in. lbs.).
  8. Install six ignition coils.
  9. Connect electrical connectors to throttle body.
  10. Connect electrical connectors at all fuel injectors. Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector.
  11. Connect necessary vacuum/vapor lines to throttle body.
  12. Connect fuel line latch clip and fuel line to fuel rail.
  13. Install air box to throttle body.
  14. Install air duct to air box.
  15. Connect battery cable to battery.
  16. Start engine and check for leaks.
Fuel Rail - Removal14 steps
⚠ WARNING
The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.
△ CAUTION
The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube (10). Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
  1. Remove fuel tank filler tube cap.
  2. Perform Fuel System Pressure Release Procedure.Service and Repair
  3. Remove negative battery cable at battery.
  4. Remove air duct at throttle body air box.
  5. Remove air box at throttle body.
  6. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. Service and Repair
  7. Remove necessary vacuum/vapor lines at throttle body.
  8. Disconnect electrical connectors at all 6 fuel injectors. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
  9. Disconnect electrical connectors at throttle body sensors.
  10. Remove 6 ignition coils. Ignition Coil - Removal
  11. Remove four fuel rail mounting bolts (1).
  12. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes.
  13. Remove fuel rail (with injectors attached) from engine.
  14. If fuel injectors are to be removed, Fuel Injector - Removal.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
FUEL RAIL📷 1
1. If fuel injectors are to be installed, refer to INSTALLATION . 2. Clean out fuel injector machined bores in intake manifold. 3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation. 4. Position fuel rail/fuel injector assembly to machined injector openings in cylinder head. 5. Guide each injector into cylinder head. Be careful not to tear injector O-rings. 6. Push right side of fuel rail down until fuel injectors have bottomed on cylinder head shoulder. Push left fuel rail down until injectors have bottomed on cylinder head shoulder. 7. Install four fuel rail mounting bolts and tighten to 11 N.m (100 in. lbs.). 8. Install six ignition coils. Refer to INSTALLATION . 9. Connect electrical connectors to throttle body.
10. Connect electrical connectors at all fuel injectors. Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. 11. Connect necessary vacuum/vapor lines to throttle body.
12.   Connect fuel line latch clip and fuel line to fuel rail.
13.   Install air box to throttle body.
14.   Install air duct to air box.
15.   Connect battery cable to battery.
16.   Start engine and check for leaks.
figure
RAIL - FUEL📷 2

Removal

CAUTION: Cleanliness cannot be overemphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high- pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead
to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. When installing new parts, lubricate them with clean engine oil or clean diesel fuel only.
1
Disconnect negative battery cable at battery. Isolate end of cable.
2
Remove dress-up cover from top of engine.
3
Disconnect electrical connector at fuel pressure sensor (1).
4
Disconnect electrical connector at fuel pressure solenoid (3).
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