Service Procedure

WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before servicing the fuel rail.

1. With the ignition key in the OFF position disconnect the battery.

Note:
To enhance customer satisfaction remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock radio settings etc.) when you have completed the service procedure.

2. Remove the fuel tank filler cap to release the fuel tank pressure.





3. Remove the protective cap from the pressure test port on the fuel rail (Figure 1).

WARNING:
Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when pressure is released from the rail.

4. Obtain the hose from the fuel pressure gauge tool set # 5069. Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure.

5. Remove the hose from the fuel rail and reinstall the test port cap.

6. Disconnect the air cleaner from the throttle body.





7. Hold the throttle lever in the wide-open position and remove the throttle cable and speed control cable from the lever (Figure 2).

8. Remove the throttle cable and speed control cable from their mounting bracket by compressing the locking tabs (Figure 2).





9. Disconnect the EGR transducer electrical connector (Figure 3).

10. Disconnect the MAP sensor electrical connector (Figure 3).

11. Disconnect the hose from the PCV valve at the rear of the intake plenum.

12. Disconnect the fuel pressure regulator vacuum line.

13. Disconnect the brake booster vacuum hose from the intake plenum nipple.

14. Disconnect the speed control vacuum line (if equipped).

15. Disconnect the vapor canister purge hose from the throttle body.

16. Disconnect the throttle position sensor and idle air control (IAC) motor electrical connectors.





17. Disconnect the EGR tube from the intake plenum (Figure 4).

18. Remove the intake plenum mounting bolts, then lift the plenum up and off the engine.

19. Cover the intake manifold to prevent foreign material from entering the engine. Then using shop air clean any loose dirt and debris from around the fuel injectors.





20. Disconnect the fuel supply and return tube quick connect fittings from the fuel rail (Figure 5).

21. Remove the screw from the fuel tube bracket and separate the fuel tubes from the bracket (Figure 5). Remove and discard the bracket.

22. Rotate the fuel injectors toward the center of the engine. Tag the fuel injector electrical connectors and then disconnect the injector connectors.





23. Remove the fuel rail mounting bolts (Figure 6). Lift the fuel rail straight up and off the engine. Cover the fuel injector openings in the intake manifold.





24. Remove the fuel injector retaining clips and then remove the injectors from the fuel rail cups (Figure 7).

25. Remove the upper and lower 0-rings from the six (6) fuel injectors.

26. Install the supplied upper and lower 0-rings on the six (6) fuel injectors.

27. Apply a light coating of clean engine oil to the upper 0-ring on each injector.

28. Install the fuel injectors onto the new fuel rail and secure them with the retaining clips (Figure 7).

29. Remove the fuel pressure regulator from the old fuel rail.

30. Remove and discard the fuel pressure regulator 0-rings.

31. Lubricate both new pressure regulator 0-rings with a light coating of clean engine oil and then install the 0-rings into the new fuel rail pressure regulator "pockets". Use a socket or similar tool to ensure that the 0-rings are properly seated.

32. Install the original fuel pressure regulator into the fuel rail and "seat" it into the 0-rings. Install the regulator hold down clamp and tighten the clamp screw to 60 in-lbs (7 N.m).

33. Apply a light coating clean engine oil to the lower 0-ring on each injector.

34. Insert the injector nozzles into the intake manifold openings. Seat the injectors by hand and then tighten the fuel rail mounting bolts to 200 in-lbs (22 N.m) (Figure 6).

35. Connect the fuel injector electrical connectors and then rotate the injectors toward the cylinder head covers.

36. Connect the fuel supply and return tubes to the new fuel rail (Figure 5).

37. Install the new fuel rail bracket and tighten the retaining screw securely (Figure 5).

38. Clean the intake manifold intake plenum and EGR tube gasket surfaces.

CAUTION:
DO NOT use metal scrapers, grinding discs or abrasives to clean aluminum components as damage to sealing surfaces may occur.

39. Using the new gasket position the intake plenum on the intake manifold. Loosely install the plenum bolts.

40. Using the new gasket loosely install the EGR tube onto the intake plenum (Figure 4).





41. Tighten the intake plenum bolts to 250 in-lbs (28 N.m) in the sequence shown in Figure 8.

42. Tighten the EGR tube mounting screws to 200 in-lbs (22 N.m).

43. Connect the speed control vacuum line (if equipped).

44. Connect the vapor canister purge hose to the throttle body.

45. Connect the PCV valve hose.

46. Connect the brake booster vacuum hose to the intake plenum nipple.

47. Connect the vacuum line to the fuel pressure regulator.

48. Connect the MAP sensor electrical connector (Figure 3).

49. Connect the EGR transducer electrical connector (Figure 3).

50. Connect the throttle position sensor and IAC motor electrical connectors.

51. Install the throttle cable and speed control cable into the mounting bracket (Figure 2).

52. Connect the throttle and speed control cables with the throttle in the wide-open position.

53. Connect the air cleaner to the throttle body.

54. Connect the negative battery cable.