Fuel Rail: Service and Repair

REMOVAL

1. Disconnect battery ground cable.
2. On vehicles equipped with automatic transmission, disconnect kickdown cable from throttle linkage.
3. On all vehicles, disconnect accelerator cable from throttle linkage.
4. Remove screws attaching accelerator cable bracket to upper intake manifold and position bracket, accelerator cable and 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 PCV hose from 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 cap and attached wires out of way.
9. Depressurize EFI fuel system using a hand operated vacuum pump. Connect pump hose to fuel system pressure regulator and apply at least 25 inches vacuum.
10. Disconnect vacuum pump from fuel pressure regulator.
11. Disconnect fuel supply line from fuel supply manifold.
12. Using tool No. T82L-9500-AH or equivalent, disconnect fuel return line.
13. Remove nut attaching fuel pulse damper to mounting bracket.
14. Cut fuel injection wiring harness routing strap at fuel pulse damper as necessary.
15. Disconnect fuel injection wiring harness connector.
16. Disconnect electrical connector from coolant temperature sender in cylinder block.
17. Remove fuel supply manifold assembly front attaching bolt.
18. Remove fuel supply manifold assembly rear attaching bolt.
19. Remove fuel supply manifold assembly by disengaging each fuel injector from lower intake manifold, then carefully pulling whole assembly out from under upper intake manifold toward front of engine.
20. Remove three Allen head attaching screws and the fuel pressure regulator from fuel supply manifold.
21. Remove each injector from fuel supply manifold and disconnect wiring harness connector from each injector.

INSTALLATION

1. Install injectors on fuel supply manifold, then install fuel pressure regulator and three attaching screws.
2. Connect wiring harness connector to each fuel injector, then position fuel supply manifold assembly under upper intake manifold and insert each injector into its opening in lower intake manifold.
3. Install front and rear fuel supply manifold attaching bolts, torquing to 15-22 ft. lbs.
4. Connect electrical connectors at coolant temperature sender and fuel injection wiring harness.
5. Install new fuel injection wiring harness routing strap on fuel pulse damper bracket as necessary.
6. Place fuel pulse damper in mounting bracket and install attaching nut.
7. Connect fuel supply line and install retaining clip, then connect fuel return line.
8. Install distributor cap and attaching screws and connect coil wire to distributor cap.
9. Connect PCV hose and the vacuum hoses to fuel pressure regulator and upper intake manifold fittings.
10. Position accelerator cable bracket on upper intake manifold and install attaching screws.
11. Connect accelerator cable to throttle linkage.
12. On vehicles equipped with automatic transmission, connect kickdown cable to throttle linkage.
13. On all vehicles, connect battery ground cable.