Fig. 6 Throttle Body Assembly

INSTALLATION

(1)Install throttle body with new gasket.

(2)Install throttle body attaching nuts. Tighten nuts to 25 NIm (225 in. lbs.) torque.

(3)Connect vacuum hoses to the throttle body.

(4)Attach harness connectors to the throttle position sensor (TPS) and the automatic idle speed (AIS) motor.

(5)Install throttle and speed control cables (if applicable).

(6)Install throttle body intake air hose. Tighten clamp to 4 NIm (30 in. lbs.) torque.

(7)Connect negative cable to battery.

FUEL INJECTOR RAIL ASSEMBLY

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 RAIL OR FUEL INJECTORS.

REMOVAL

(1)Perform fuel system pressure release procedure.

(2)Disconnect negative battery cable.

CAUTION: Place a shop towel should under the fuel hoses to catch any fuel spillage.

(3)Remove quick connect fittings from the chassis fuel tubes (Fig. 7). Refer to Quick Connect Fittings in the Fuel Delivery Section of this manual.

(4)Disconnect the vacuum hose from the fuel pressure regulator (Fig. 8).

Fig. 7 Quick Connect Fittings

(5)Disconnect the fuel injector wiring harness from the main harness.

(6)Place oil separator bracket out of the way and remove the fuel rail support bracket screws.

Fig. 8 Fuel Rail Fasteners

(7)Remove the fuel rail and injector assembly by pulling rail so that the injectors come straight out of their ports. Do not damage the rubber injector O-rings after removing the fuel rail.

Do not remove fuel injectors until fuel rail assembly has been completely removed from the vehicle.

(8)Cover or plug the injector ports with while servicing the injectors (Fig. 9).

INSTALLATION

(1)Ensure the injectors are seated into the receiver cup, with the lock ring in place.

(2)Ensure the injector wiring connectors are fully inserted into the fuel injectors.

(3)Make sure the injector holes are clean and all plugs have been removed (Fig. 9).

(4)Lubricate the injector O-rings with a drop of clean engine oil.