Fuel Rail: Service and Repair
REMOVAL:1. Disconnect the negative battery cable.
2. Disconnect the accelerator cable.
3. Disconnect the throttle cable (on A/T equipped vehicles).
4. Disconnect the ground strap from the rear of the engine.
5. Disconnect the following parts:
a. No.1 and No.2 PCV hoses
b. Brake booster hose
c. Air control valve hoses (on P/S equipped vehicles)
d. VSV hoses (on A/C equipped vehicles)
e. EVAP hoses
f. EGR vacuum modulator hose
g. EGR valve hose
h. Fuel pressure up hose
i. Reed valve hose
j. Pressure regulator hose
k. Vacuum hoses from the throttle body
l. No.2 and No.3 water bypass hoses from the throttle body
m. Disconnect the No.1 oil cooler hose from the intake manifold (if equipped with oil cooler)
n. Disconnect the No.1 water bypass hose from the intake manifold (if not equipped with oil cooler)
6. Remove the EGR vacuum modulator.
7. Disconnect the following connectors:
a. Cold start injector connector
b. Throttle position sensor connector
c. EGR gas temperature sensor connector (California model only)
8. Remove the union bolt holding the cold start injector pipe to the air intake plenum.
9. Remove the bolts holding the No.1 EGR pipe to the air intake plenum.
10. Remove the bolts holding the manifold stay to the air intake plenum.
Removing The Air Intake Plenum:
11. Remove the four bolts, two nuts, bond strap and fuel hose clamp.
12. Remove the air intake plenum with the throttle body, resonator and gasket.
13. Disconnect the following wires:
a. Knock sensor wire
b. Oil pressure sender gauge or switch wire
c. Starter wire (Terminal 50)
d. Transmission wires
e. Compressor wires (on A/C equipped vehicles)
f. Injector wires
g. Water temperature sender gauge wire
h. OD temperature switch wire (on A/T equipped vehicles)
i. Igniter wire
j. VSV wires
k. Cold start injector time switch wire
l. Water temperature sensor wire
14. Remove the bolt, union bolt, two gaskets, and remove the fuel hose from the fuel rail.
15. Remove the two fuel rail mounting bolts.
16. Lift the Fuel Rail with the injectors from the cylinder head.
CAUTION: Be careful that the injectors do not drop from the Fuel Rail. Damage to the injector tip could result.
17. Remove the four insulators and two spacers from the cylinder head.
18. When the Fuel Rail is safely over a workbench, pull the injectors from the Fuel Rail.
INSTALLATION:
1. Install new grommets and O-rings to the injectors.
2. Apply a thin coat of gasoline to the O-rings and install the injectors into the fuel rail.
Correct Installation Of Fuel Injectors To Fuel Rail:
3. Install the four insulators into the injector holes of the intake manifold.
4. Install the injectors together with the fuel rail to the manifold.
Installing The Fuel Rail/Fuel Injectors Into The Intake Manifold:
5. Make sure that the injectors rotate smoothly.
Rotating The Injectors To Insure Proper Installation:
CAUTION: If the injectors do not rotate smoothly, the O-rings may not be installed correctly. Try repositioning the O-rings on the injectors.
6. Install the fuel rail mount bolts and torque to 14 ft.lbs. (19 N-m).
7. Install the fuel hose to the fuel rail with the clamp.
Installing The Fuel Hose:
8. Using two new gaskets, install the union bolt and torque to 33 ft.lbs. (44 N-m).
9. Connect the wires that were disconnected in step 13 of the removal procedure.
10. Using a new gasket, install the air intake plenum, throttle body, fuel hose clamp, resonator and bond strap assembly with the four mounting bolts and two nuts.
NOTE: It will be necessary at this time to place a new No.1 EGR pipe gasket on the intake manifold.
11. Connect the air intake plenum and stay with a bolt.
Removing The Air Intake Plenum:
12. Install the bolts holding the EGR valve to the chamber.
13. Using a new gasket, install the cold start injector pipe.
14. Reconnect the connectors that were disconnected in step 7 of the removal procedure.
15. Install the EGR vacuum modulator.
16. Reconnect the parts that were disconnected in step 5 of the removal process.
17. Connect the ground strap to the rear of the engine.
18. Connect the throttle cable (on A/T equipped vehicles).
19. Connect the accelerator cable.
20. Reconnect negative battery cable.
21. Start engine and check for fuel leaks.