Fuel Rail: Service and Repair

FUEL INJECTION SUPPLY MANIFOLD

REMOVAL

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel pressure must be relieved. Failure to follow these instructions may result in personal injury.

1. Disconnect the battery ground cable.
2. Disconnect the air cleaner outlet tube.
3. Relieve the fuel pressure.
4. Disconnect the fuel line.
5. Remove the throttle body.







6. Remove the idle air control (IAC) hose and position it out of the way.







7. Remove the positive crankshaft ventilation (PCV) hose.







8. Disconnect the four RH fuel injector electrical connectors.







9. Disconnect the IAC electrical connector and the main chassis vacuum hose.







10. Remove the hose.







11. Squeeze the two locking tabs, and remove the accelerator cable and the speed control cable (if equipped) and position aside.







12. Disconnect the fuel pressure sensor electrical connector and the vacuum hose.







13. Disconnect the ground wire.







14. Disconnect the LH fuel injector electrical connectors.







15. Remove the exhaust vacuum regulator (EVR) solenoid vacuum lines.







16. Remove the bolts from the EGR pressure transducer bracket and position aside.
17. Remove the EGR to exhaust manifold tube.







18. Disconnect the exhaust valve recirculation (EGR) vacuum line.







19. NOTE: The LH side is shown, the RH is similar.

Remove the four bolts and remove the supply manifold with the fuel injectors attached.

INSTALLATION

1. NOTE: The LH side is shown, and the RH is similar.

Install the supply manifold and tighten the four bolts.







2. Connect the EGR vacuum line.
3. Install the EGR to exhaust manifold tube.

4. NOTE: The engine is removed for clarity.

Position the EVR bracket and tighten the bolts.







5. Connect the EVR solenoid vacuum lines.







6. Connect the LH fuel injector electrical connectors.







7. Connect the ground wire.







8. Connect the fuel pressure sensor electrical connector and the vacuum hose.







9. NOTE: Make sure the locking clips are fully engaged into the bracket.

Reposition the accelerator cable and the speed control cable (if equipped) and install the cables into the bracket.







10. Connect the hose.







11. Connect the IAC electrical connector and install the main chassis vacuum hose.







12. Connect the four RH fuel injector electrical connectors.







13. Connect the PCV hose.







14. Position the IAC hose and connect the hose.
15. Install the throttle body.
16. Connect the fuel line.
17. Connect the air cleaner outlet tube.
18. Connect the battery ground cable.