Fuel Rail: Service and Repair

WARNING: THE MPI FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 330 kPa (49 PSI), 3.3L USES APPROXIMATELY 379 kPa (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL RAIL OR FUEL INJECTORS.

REMOVAL
1. Perform fuel system pressure release procedure.
2. Disconnect negative cable from battery.
3. Remove intake manifold cover.

Air Inlet Resonator:

4. Remove air inlet resonator.

Throttle Cable Attachment:

5. Remove throttle cable and speed control cable (if equipped) from throttle lever and bracket.

Electrical And Vacuum Connection To Throttle Body:

6. Disconnect idle air control motor and Throttle Position Sensor (TPS) electrical connectors.

Vacuum Connections:

7. Remove vacuum hose harness from throttle body and intake manifold.

EGR Tube:

8. Remove EGR tube to intake manifold flange bolts.
9. Remove cylinder head to intake plenum strut.

Map Sensor:

10. Disconnect electrical connector from the MAP sensor.
11. Remove engine mounted ground strap.

Fuel Line Quick Disconnect:

12. Remove the fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings.

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

Ignition Coils:

13. Remove Direct Ignition System (DIS) coils.
14. Remove generator bracket to intake manifold bolt.

Intake Manifold Bolts:

15. Remove intake mounting manifold bolts and rotate manifold back over rear valve cover.

Fuel Rail Attaching Bolts:

16. Cover intake manifold with suitable cover when servicing.
17. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer bracket to allow fuel tube removal clearance.

Camshaft Position Sensor Connector:

18. Disconnect camshaft position sensor and engine coolant temperature sensor.

Fuel Rail Removal:

19. 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.
5. Install fuel tube retaining bracket screw. Tighten screw to 4 Nm (35 in. lbs.) torque.
6. Connect electrical connectors to camshaft position sensor and engine coolant temperature sensor.
7. Remove covering on lower intake manifold and clean surface.
8. Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight.
9. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts (do not tighten.)
10. Following the tightening sequence, tighten intake manifold bolts to 28 Nm (250 in. lbs.) torque.
11. Tighten generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.) torque.
12. Tighten the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.) torque.
13. Connect ground strap and MAP sensor electrical connector.
14. Connect vacuum harness to intake plenum. Connect PCV system hoses.
15. Using a new gasket, connect the EGR tube to the intake manifold plenum. Tighten screws to 22 Nm (200 in. lbs.) torque.
16. Connect electrical connectors to the TPS and idle air control motor.
17. Connect vacuum harness to throttle body.
18. Install the direct ignition system (DIS) coils. Tighten fasteners to 12 Nm (105 in. lbs.) torque.
19. Install fuel hose quick connector fitting to chassis tubes. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. Push the fitting onto the chassis tube until it clicks into place. Pull on the fitting to ensure complete insertion.
20. Install throttle cable and speed control cable (if equipped).
21. Install air inlet resonator.
22. 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.

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