Fuel Rail: Service and Repair

Fig. 20 Fuel supply manifold front retaining bolt location:

Fig. 21 Fuel supply manifold rear attaching bolt location:

1. Disconnect battery ground cable.
2. On vehicles equipped with automatic transmission, disconnect kickdown cable from throttle linkage.
3. On all models, disconnect accelerator cable from throttle linkage.
4. Remove screws attaching accelerator cable bracket to upper intake manifold, then position bracket, accelerator cable and the automatic transmission kickdown cable, if equipped, out of way.
5. Disconnect fuel pressure regulator vacuum hose from fuel pressure regulator and the upper intake manifold fitting.
6. Disconnect positive crankcase ventilation (PCV) hose at upper intake manifold fitting.
7. Disconnect coil wire from distributor cap and position out of way.
8. Remove distributor cap attaching screws and the cap, positioning out of way.
9. Using suitable vacuum pump, depressurize fuel system. Connect pump hose to fuel system pressure regulator and apply at least 25 inches of vacuum. Fuel supply lines will remain pressurized for some period of time after engine is shut off. System pressure must be relieved before disconnecting any fuel lines.
10. Disconnect vacuum pump from fuel pressure regulator.
11. Disconnect fuel supply line from fuel supply manifold.
12. Using tool T822-9500-AH or equivalent, disconnect fuel return line.
13. Remove fuel pulse damper to mounting bracket attaching nut.
14. Cut fuel injection wiring harness routing strap at fuel pulse damper bracket, if necessary.
15. Disconnect fuel injector wiring harness connector.
16. Disconnect electrical connector from coolant temperature sender at cylinder block.
17. Remove fuel supply manifold assembly front retaining bolt, Fig. 20.
18. Remove fuel supply manifold assembly rear attaching bolt, Fig. 21.
19. Remove fuel supply manifold assembly by disengaging each fuel injector from lower intake manifold, then carefully pulling the whole assembly out from under the upper intake manifold toward front of engine.
20. Remove three Allen head attaching screws and the fuel pressure regulator from the fuel supply manifold.
21. Remove each injector from fuel supply manifold.
22. Disconnect electrical connector at each injector.
23. Reverse procedure to install, torquing fuel supply manifold attaching bolts to 15-22 ft. lbs.