Fuel Rail: Service and Repair

Fig. 11 Fuel injection components. All 1984-86 models & 1987 models w/Turbo I:

Fig. 12 Fuel rail & injector assembly. All 1984-86 models & 1987 models w/Turbo I:

All 1984-86 Models & 1987 Models W/Turbo I
1. Release fuel system pressure.
2. Loosen supply hose clamps at fuel rail inlet and remove hose.
3. Disconnect fuel pressure regulator vacuum hose from intake manifold vacuum tree.
4. Remove fuel pressure regulator bolts from intake manifold bracket, Fig. 11.
5. Loosen fuel rail to pressure regulator hose clamp at rail end and remove hose and regulator.
6. Remove screw from fuel rail to valve cover bracket.
7. Disconnect fuel injector wiring harness.
8. Remove clips from fuel injector heat shield, Fig. 11.
9. Remove fuel rail to intake manifold bolts, then fuel rail and injector assembly by pulling rail so that injectors come straight out of their ports. Take care not to damage rubber injector O-rings.
10. Remove fuel rail assembly from vehicle, Fig. 12. Do not remove fuel injectors until fuel rail assembly has been completely removed from vehicle.
11. Be sure injectors are seated in receiver cup with lock ring in place.
12. Make sure injector openings are clean and that any plugs have been removed.
13. Apply drop of oil to injector O-rings.
14. Draw injector assembly into intake manifold taking care to seat each injector in its hole. Once all injectors are seated properly, torque bolts to 250 inch lbs.
15. Connect injector wiring harness to injectors.
16. Install heat shield clips.
17. Connect injector wiring harness to main harness.
18. Install fuel rail to valve cover bracket.
19. Reconnect fuel pressure regulator vacuum hose to vacuum tree.
20. Install fuel pressure regulator hose clamp and hose to fuel rail.
21. Install fuel pressure regulator on intake manifold bracket and tighten screws.
22. Connect fuel supply hose and clamp to fuel rail inlet. Torque clamp to 10 inch lbs. Check that all ground straps, hoses, and wiring harnesses are located properly.
23. Connect battery ground cable.
24. Check system for leaks.

Fig. 13 Fuel rail assembly. 1987 models w/Turbo II:

1987 Models W/Turbo II
1. Release fuel system pressure, then disconnect battery ground cable.
2. Remove air cleaner assembly, then disconnect detonation (knock) sensor and fuel injector electrical connectors.
3. Disconnect AIS motor and TPS electrical connectors from throttle body.
4. Remove throttle body and PCV system vacuum hoses.
5. Loosen fuel supply hose clamp at fuel rail inlet, then remove hose.
6. Loosen fuel return hose clamp at fuel pressure regulator, then remove hose.
7. Remove EGR tube attaching nut from EGR valve.
8. Remove accelerator cable, then disconnect upper plenum support bracket at battery ground cable on cylinder head.
9. Remove intake manifold upper plenum attaching bolts, then the upper plenum and gasket from lower manifold.
10. Remove fuel pressure regulator attaching nuts, then the fuel pressure regulator from rail.
11. Remove fuel rail to valve cover bracket attaching screws, then disconnect detonation (knock) sensor electrical connector.
12. Remove fuel rail to intake manifold attaching screws, then the fuel rail and injector assembly by pulling rail so that injectors come straight out of there ports. Use caution not to damage rubber injector O-rings during removal.
13. Remove fuel rail assembly from vehicle, Fig. 13.
14. Reverse procedure to install, noting the following:
a. Lubricate injector and fuel pressure regulator O-ring with clean oil to facilitate installation.
b. Torque fuel rail attaching bolts to 250 inch lbs.
c. Torque fuel pressure regulator attaching bolts to 65 inch lbs.
d. Torque upper plenum to intake manifold attaching bolts to 200 inch lbs. and upper plenum support bracket to 40 ft. lbs.