Fuel Rail: Service and Repair

Fig. 9 Intake Manifold Plenum Sensors And Left Plenum Support Bolt:

REMOVAL
1. Disconnect negative cable from auxiliary jumper terminal.

WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle.

2. Release fuel system pressure. Service and Repair

WARNING: Wrap shop towels around hose to catch any gasoline spillage.

3. Disconnect fuel supply tube from rail. Service and Repair
4. Unplug connectors from MAP and intake air temperature sensors Fig. 9.
5. Remove plenum support bracket bolt located rearward of MAP sensor Fig. 9.

Fig. 3 Air Inlet Resonator:

6. Remove bolt holding air inlet resonator to intake plenum Fig. 3.
7. Loosen throttle body air inlet hose clamp.
8. Release snaps holding air cleaner housing cover to housing.
9. Remove air cleaner cover and inlet hoses from engine.

Fig. 10 Throttle Position Sensor:

Fig. 11 Air Control Motor:

10. Unplug TPS and idle air control motor connectors Fig. 10 and 11.
11. Pry retainer tab back on throttle cable and slide cable out of bracket Fig. 12.

Fig. 12 Throttle Cable Attachment:

12. Slide Speed control cable out of bracket, if equipped Fig. 12.

Fig. 13 EGR Tube And Right Plenum Support Bolt:

13. Remove EGR tube from intake plenum Fig. 13.
14. Remove plenum support bracket bolt located rearward of EGR tube Fig. 13.
15. Remove 7 bolts holding upper intake plenum and remove plenum.
16. Disconnect electrical connectors from fuel injectors.

Fig. 13 EGR Tube And Right Plenum Support Bolt:

17. Remove 4 bolts holding fuel rail Fig. 14.

Fig. 15 Fuel Rail Spacers:

18. Lift fuel rail off engine. There are spacers under each fuel rail bolt Fig. 15.

INSTALLATION
1. Apply a light coating of clean engine oil to the 0-ring on the nozzle end of each injector.

CAUTION: Make sure spacers are located under each fuel rail mounting position.

2. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 12 Nm (8 ft. lbs.).
3. Attach electrical connectors to fuel injectors.
4. Connect fuel supply tube to fuel rail. Service and Repair
5. Install new gasket and position upper intake plenum. Tighten plenum bolts to 18 Nm (13 ft. lbs.) torque.
6. Install bolts at plenum support brackets. Tighten bolts to 18 Nm (13 ft. lbs.).
7. Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 Nm (95 in. lbs.) torque.
8. Install throttle cables.
9. Attach electrical connectors to sensors.
10. Tighten air inlet tube clamps to 3 Nm ± 1 (25 ± 5 in. lbs. ) torque.
11. Connect negative terminal to auxiliary jumper terminal.