Fuel Rail: Service and Repair

REMOVAL

WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Disconnect the fuel lines.
4. Remove the throttle body.
5. Remove the EGR valve to exhaust manifold tube.
6. Remove the drive belt.
7. Disconnect the main fuel shut-off solenoid connector.







8. Disconnect the generator cable, electrical connector, and harness pin-type retainer.







9. Remove the bolts and the generator mounting bracket.







10. Remove the bolts.







11. Unclip the accelerator cable and the speed control actuator cable from the two crash brackets and position out of the way.







12. Separate the LH heated oxygen sensor and the transmission electrical connector from the bracket at the rear of the cylinder head.







13. Separate the fuel charging wiring pin-type retainer from the crash bracket.







14. Remove the wiring bracket.
^ Disconnect the wiring connectors.
^ Separate the transmission harness from the stud.
^ Remove the nut and the bolt and remove the bracket.







15. Disconnect the vacuum lines and position out of the way.







16. Remove bolt and stud and remove the crash bracket.







17. Disconnect the ground connector from the RH rear stud.







18. Disconnect generator harness locator retainer from LH front stud.







19. Disconnect the eight fuel injector electrical connectors.







20. Disconnect the crankcase ventilation tube and position out of the way.







21. Disconnect the vacuum line.







22. Disconnect the vacuum line from the Evaporative Emission (EVAP) canister purge valve.







23. Disconnect the EGR vacuum regulator solenoid.







24. Remove the four studs.
25. Remove the fuel injection supply manifold and the fuel injectors as an assembly.

INSTALLATION
1. Lubricate the fuel injector pockets with clean engine oil to aid installation.

CAUTION: Use O-rings that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings.

2. Install the fuel injection supply manifold and the fuel injectors as an assembly.







3. Tighten the fuel injection supply manifold studs to specification.
4. Install the crash bracket.







5. Install the bolt and the stud.







6. Connect the EGR vacuum regulator solenoid.







7. Connect the vacuum line to the evaporative emission canister purge valve.







8. Connect the vacuum line.







9. Connect the crankcase ventilation tube.







10. Connect the eight fuel injector electrical connectors.







11. Connect the vacuum lines.







12. Install the fuel supply retaining bracket.
^ Install the transmission harness retainer to the stud.
^ Reconnect the wiring connectors.
^ Install nut and bolt.







13. Attach the LH heated oxygen sensor connector.







14. Install fuel charging pin-type retainer to the crash bracket.







15. Clip the accelerator cable and the speed control actuator cable to the two crash brackets.







16. Install the bolts.







17. Install the generator mounting bracket and tighten the bolts.







18. Connect ground connector to RH rear stud.







19. Connect the generator harness location retainer to the LH front stud.
20. Install the drive belt.
21. Install the EGR valve to exhaust manifold tube.
22. Install the throttle body.
23. Connect the fuel lines.
24. Connect the battery ground cable.