Fuel Rail: Service and Repair
REMOVAL
1. Thoroughly clean the engine.
2. Disconnect electrical connectors at air bypass valve, throttle position sensor, EGR sensor and air charge temperature sensor (ACT).
3. Remove air inlet tube from air cleaner to throttle body.
4. Remove snow/ice shield to expose throttle linkage. disconnect throttle cable from ball stud.
5. Disconnect upper intake manifold vacuum connectors; both the front and rear fittings including the EGR valve and vacuum line to fuel presure regulator.
6. Disconnect PCV closure tube from under throttle body and disconnect PCV vacuum tube from under the manifold.
7. Remove canister purge line from fitting near power steering pump.
8. Disconnect EGR tube from EGR valve by removing flange nut.
9. Loosen bolt which retains A/C line at the upper rear of the upper manifold and disengage retainer.
10. Remove six upper intake manifold retaining bolts.
11. Remove upper intake and throttle body as an assembly form the lower intake manifold.
12. Remove fuel line retainer clips from fuel inlet and lines.
13. Disconnect the fuel supply and return line connections at the fuel supply manifold.
14. Remove four fuel supply manifold retaining bolts.
15. Carefully disengage fuel supply manifold from lower intake manifold. The fuel injectors are retained in the fuel supply manifold with clips.
Intake Manifold Assembly:
16. Remove retainer clips and inspect for corrosion and damage.
17. Remove injector from fuel supply manifold and wipe cup with a clean, dry cloth.
INSTALLATION
1. Make sure the injector caps are clean and free of contamination. Inspect injector o-rings. Replace if required.
CAUTION: Do not attempt to clean the injector pintle or metering orifice with brushes or tools.
2. Carefully wipe the injector recesses in the manifold and make sure they are free of contamination. Lightly grease the recesses.
CAUTION: Do not use silicone grease to lubricate o-rings. Silicone grease can plug injectors.
3. Locate the three injectors on the RH recesses of the intake manifold. Then the three on the left.
4. Position the fuel supply manifold and press down firmly until the attachment holes line up.
5. Install the four retaining bolts and tighten. Refer to SPECIFICATIONS.
6. Install the fuel injector retaining clips to the injectors.
7. Install the crossover fuel hose. Install the fuel supply and return line couplings as follows:
a. Ensure that garter spring is in cage of male fitting. If a garter spring is missing, install a new spring by pushing it into cage opening. If garter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring.
b. Clean all dirt or foreign material from both pieces of coupling.
WARNING: Use only the specified o-rings as they are made of a special material. The use of any o-ring may allow the connection to leak intermittently during vehicle operation.
c. Lubricate male fitting and o-rings and inside of female fiting with clean engine oil.
d. Install plastic indicator ring into cage opening if indicator ring is to be used.
e. Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting. If plastic indicator ring is used, it will snap out of cage opening when coupling is connected to indicate engagement.
f. If indicator ring is not used, ensure coupling engagement by visually checking to be sure garter spring is over flared end of female fitting.
8. Install the spring-lock coupling retaining clips on fuel inlet and return fittings. Install fuel line safety clips.
9. Install the upper intake manifold. As outlined in this section.
10. Connect the battery ground cable.
11. Turn the ignition key to the on position for two or three seconds to pressurize the fuel rail, and check for fuel leaks.
12. Install the fuel injector wiring harness to the injectors, and install the vacuum supply hose to the fuel pressure regulator.