Ä

(6)Connect electrical connector to detonation (knock) sensor (Fig. 8).

(7)Connect vacuum hose to fuel pressure regulator. Replace clamp.

(8)Close fuel tube clip around fuel tubes and install fastener.

(9)Lubricate the ends of the chassis fuel tubes with clean 30 weight engine oil. Connect fuel supply and return hoses to chassis fuel tube assembly. Pull back on the quick connect fittings to ensure complete insertion. Refer to Fuel Hoses, Clamps, and Quick Connect Fittings in the Fuel Delivery section of this group.

(10)Install vacuum, vapor hose onto intake manifold nipple. Replace clamp (Fig. 7).

(11)Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(12) With the DRB II use the ASD Fuel System Test to pressurize system and check for leaks.

FUEL INJECTOR

The fuel rail must be removed to service the injectors. Refer to Fuel Injector Rail Assembly in this section.

REMOVAL

(1) Disconnect electrical connector from injector (Fig. 10).

FUEL SYSTEMS 14 - 73

(2) Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 11).

Fig. 11 Fuel Rail and Injector Assembly

(3)Remove injector lock ring from fuel rail and injector. Pull injector straight out of fuel rail receiver cup.

(4)Check injector O-ring for damage. Replace damaged O-rings. If injector is reused, install a protective cap on the injector tip to prevent damage.

(5)Repeat steps for remaining injectors.

INSTALLATION

(1)Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.

(2)Being careful not to damage the O-ring, install injector top end into fuel rail receiver cup.

(3)Install injector lock ring by sliding open end into slot of the injector and onto the receiver cup ridge into the side slots of ring (Fig. 10).

(4)Repeat steps for remaining injectors.

(5)Install injector wiring harness to injectors and fasten into wiring clips (Fig. 12).

FUEL PRESSURE REGULATOR

WARNING: THE 2.5L TURBO I FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 380 KPA (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL PRESSURE REGULATOR.