Fuel Rail: Service and Repair

REMOVAL
1. Perform fuel system pressure release procedure before servicing or starting repairs.
2. Disconnect negative cable from battery.
3. Remove air cleaner inlet hose from throttle body.
4. Remove throttle cable and speed control cable (if equipped) from throttle lever.
5. Remove throttle cables from bracket by compressing retaining tabs.
6. Remove connector from throttle position sensor.
7. Remove connector from idle air control motor.

Fig. 28 Vacuum Fitting On Rear Of Intake Manifold:

Fig. 29 Electrical And Vacuum Connections:

8. Remove vacuum lines from intake plenum fittings (Fig. 28) and (Fig. 29).
9. Remove connector from intake air temperature sensor (Fig. 29).

Fig. 30 MAP Sensor:

10. Remove connector from MAP sensor (Fig. 30).

Fig. 31 Fuel Link Quick Disconnect:

11. Remove fuel hose quick connect fitting from the chassis tube (Fig. 31). Place a shop towel under the connections to absorb any fuel spilled from the fitting.

WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.

12. Remove bolt holding bottom of intake support bracket.

Fig. 32 Intake Manifold Attaching Points:

13. Remove intake manifold screws (Fig. 32).
14. Remove fuel rail attaching bolts.
15. Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports.

INSTALLATION
1. Ensure injector holes are clean. Replace O-rings if damaged.
2. Lubricate injector O-rings with a drop of clean engine oil to ease installation.
3. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
4. Install the fuel rail mounting bolts. Tighten bolts to 22 Nm (200 in. lbs.) torque (Fig. 32).
5. Install a new intake manifold gasket.
6. Position intake manifold.
7. Tighten retaining bolts starting at center and progressing outward in both directions to 23 Nm (200 in. lbs.) (Fig. 32). Repeat this procedure until all bolts are at specified torque.
8. Install fuel hose quick connector fitting to chassis tubes. Push the fitting onto the chassis tube until it clicks into place. Pull on the fitting to ensure complete insertion.
9. Install intake support bracket bolts and tighten.
10. Connect MAP sensor electrical connector.
11. Connect intake air temperature sensor electrical connector.
12. Install vacuum lines to the intake manifold fitting.
13. Connect idle air control motor electrical connector.
14. Connect throttle position sensor electrical connector.
15. Install throttle and speed control cables to bracket.
16. Install throttle and speed control cables to throttle lever
17. Install air cleaner hose to throttle body and tighten clamp.
18. Connect negative battery cable.
19. Use the DRB scan tool to pressurize the fuel system. Check for leaks.