Fuel and Emission Control Systems

REMOVAL





1. Remove screws attaching EGR tube to intake manifold.





2. Remove EGR valve mounting screws. Remove EGR valve and transducer.





3. Disconnect purge hose from throttle body.
4. Remove throttle body mounting bolts. Remove throttle body.
5. Remove gaskets. Clean gasket mating surfaces.
6. Release fuel system pressure. Refer to Powertrain Management; Testing and Inspection.
7. Remove fuel rail mounting screws. Access screws through the space between the intake manifold plenum runners.





8. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold.
9. Remove fuel injector retainer.
10. Pull injector out of fuel rail. Replace fuel injector O-rings.

INSTALLATION
1. Apply a light coating of clean engine oil to the upper O-ring.
2. Install injector in cup on fuel rail.
3. Install retaining clip.
4. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
5. Insert fuel injector nozzle into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws.
6. Connect fuel supply tube to fuel rail.
7. Install throttle body and new gasket on intake manifold. Tighten mounting bolts.





8. Connect purge hose nipple on throttle body.
9. Loosely install EGR valve with a new gasket. Install new gasket between EGR tube and EGR valve.
10. Finger tighten EGR tube fasteners.
11. Tighten EGR valve mounting screws to 22 Nm (16 ft. lbs.) torque.
12. Tighten EGR tube fasteners to 11 Nm (8 ft. lbs.) torque.
13. Connect vacuum supply tube to solenoid.