Fuel Rail: Service and Repair

***UPDATED BY TSB #F00193, JANUARY 11, 1993

NOTE: Obtain code number and deactivate audio anti-theft system before disconnecting battery. Refer to Adjustments.

WARNING:Before disconnecting any fuel line, release fuel pressure with the following procedure. Plug hoses while they are disconnected.

RELIEVING FUEL SYSTEM PRESSURE

Relieving Fuel System Pressure:

1. Start engine.
2. Disconnect fuel pump relay (circuit opening relay) connector.
3. After engine stalls, turn ignition "OFF."
4. Reconnect fuel pump relay connector.

INJECTOR AND/OR O-RING REPLACEMENT

Injectors, Fuel Rail, And Pressure Regulator:

1. Relieve fuel system pressure as described above.
2. Disconnect negative battery terminal.
3. Remove air valve.
4. Remove PCV hose.
5. Disconnect vacuum hose from pressure regulator.
6. Disconnect injector connectors.
7. Remove pressure regulator.
8. Lift injector/fuel rail assembly from vehicle.

Injector And O-Ring Replacement:

Fuel Injector:

9. Install in reverse order of removal and note the following:
a. Use new injector O-rings and insulators.
b. Apply a thin coating of gasoline to O-rings before installing.
10. Tighten fuel rail mounting bolts to 14 - 19 ft lb (19 - 25 Nm).

FUEL SYSTEM PRIMING

Fuel System Priming:

NOTE: After releasing fuel system pressure, prime system to avoid excess cranking when first starting the engine.

1. Connect a jumper wire across diagnosis connector terminals "F/P" and "GND."
2. Turn ignition "ON" for approximately 10 seconds and check for fuel leaks.
3. Turn ignition "OFF" and remove jumper wire.
4. Repair any leaks that may have been detected and recheck before starting engine.