Fuel Rail: Service and Repair

WARNING: THE MPI FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 330 kPa (48 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL RAIL OR FUEL INJECTORS.

REMOVAL
1. Perform the Fuel Pressure Release Procedure.
2. Disconnect negative cable from battery.

Air Inlet Resonator:

3. Remove air inlet resonator.

Throttle Cable Attachment:

4. Remove throttle cable.
5. Disconnect electrical connectors from the idle air control motor and Throttle Position Sensor (TPS).

Electrical And Vacuum Connection To Throttle Body:

6. Remove vacuum hose harness from throttle body.

Coolant Temperature Sensor Electrical Connections:

7. Remove electrical connector from the coolant temperature sensor.
8. Remove vacuum connections from air intake plenum vacuum connector.

Fuel Line Quick Disconnect:

9. Remove the fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. Place a shop towel under the connections to absorb any fuel spilled from the fitting.

Electrical And Vacuum Connection To Throttle Body:

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

Air Intake Plenum To Intake Manifold Attaching Fasteners:

10. Remove air intake plenum to intake manifold mounting fasteners.
11. Remove ignition coil.

Removing Air Intake Plenum:

12. Remove air intake plenum.
13. Cover intake manifold while servicing injector fuel rail.
14. Disconnect fuel injector wiring harness from engine wiring harness.

CAUTION: Do not damage the injector O-Rings when removing the injectors and fuel rail assembly.

15. Remove fuel rail mounting bolts. Lift fuel rail assembly off of intake manifold.

INSTALLATION
1. Ensure injectors are seated into the receiver cup of fuel rail with lock ring in place.
2. Make sure the injector holes in the manifold are clean.
3. To ease installation, lubricate injector O-ring with a drop of clean engine oil.
4. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports.
5. Install fuel rail attaching bolts. Tighten bolts to 13 Nm (115 in. lbs.) torque.
6. Install fuel supply and return tube holddown bolt and the vacuum crossover tube holddown bolt. Tighten bolts to 10 Nm (95 in. lbs.) torque.
7. Connect fuel injector wiring harness to engine wiring harness.
8. Remove covering from lower intake manifold and clean surface.
9. Place intake manifold gaskets with beaded sealer upon lower manifold. Put air intake in place. Install ignition coil. Install attaching fasteners and tighten to 13 Nm (115 in. lbs.) torque.
10. Connect fuel line to fuel rail.
11. Connect vacuum harness to air intake plenum.
12. Connect coolant temperature sensor electrical connector to sensor.
13. Connect PCV and brake booster supply hose to intake plenum.
14. Connect idle air control motor and Throttle Position Sensor (TPS) electrical connectors.
15. Connect vacuum vapor harness to throttle body.
16. Install throttle cable.
17. Install air inlet resonator.
18. Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position.

19. With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.