(5) Connect negative cable to battery.

FUEL INJECTOR RAIL ASSEMBLY

REMOVAL

(1)Perform fuel system pressure release procedure before servicing or starting repairs. Refer to Fuel System Pressure Release Procedure in this section.

(2)Disconnect negative cable from battery.

(3)Remove air cleaner and hose assembly (Fig. 1).

(4)Remove throttle cable (Fig. 6). Remove wiring harness from throttle cable bracket and intake manifold water tube.

Fig. 6 Throttle Cable Attachment

(5)Disconnect automatic idles speed (AIS) motor and throttle position sensor (TPS) electrical connectors (Fig. 7). Refer to Automatic Idle Speed motor and Throttle Position Sensor in this section.

(6)Remove vacuum hose harness from throttle body (Fig. 7).

(7)Remove PCV and brake booster vacuum hoses from air intake plenum.

(8)Remove EGR tube to intake manifold flange bolts (Fig. 8).

(9)Remove vacuum harness connectors from intake plenum (Fig. 8).

(10)Remove cylinder head to intake plenum strut (Fig. 8).

(11)Disconnect electrical connectors from the MAP sensor and heated oxygen sensor electrical connection. Remove the engine mounted ground strap (Fig. 9).

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

Fig. 7 Electrical and Vacuum Connection to Throttle Body

Fig. 8 EGR Tube

(12)Remove the fuel hose quick connect fittings from the chassis tubes. Refer to Fuel Hoses,

Clamps and Quick Connect Fittings in the Fuel Delivery Section of this Group. Place a shop towel under the connections to absorb any fuel spilled. fittings.

(13)Remove direct ignition system (DIS) coils and alternator bracket to intake manifold bolt (Fig. 10).

Fig. 9 MAP Sensor Electrical Connector

Fig. 10 Ignition Coils

(14)Remove intake mounting manifold bolts and rotate manifold back over rear valve cover (Fig. 11).

(15)Cover intake manifold with suitable cover when servicing (Fig. 12).

(16)Remove vacuum harness connector from Fuel Pressure Regulator.

(17)Remove fuel tube retainer bracket screw and fuel rail attaching bolts (Fig. 12). Spread the retainer bracket to allow fuel tube removal clearance.

(18)Remove fuel rail injector wiring clip from the alternator bracket (Fig. 13).

(19)Disconnect cam sensor, coolant temperature sensor, and engine temperature sensors (Fig. 13).

(20)Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports (Fig. 14).

Fig. 11 Intake Manifold Bolts

Fig. 12 Fuel Rail Attaching Bolts

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 (Fig. 14).

(4)Install the fuel rail mounting bolts. Tighten bolts to 22 NIm (200 in. lbs.) torque (Fig. 12).

(5)Install fuel tube retaining bracket screw. Tighten screw to 4 NIm (35 in. lbs.) torque.

(6)Connect electrical connectors to cam sensor, coolant temperature sensor and engine temperature sensors (Fig. 13).

(7)Install fuel injector harness wiring clips on the alternator bracket and intake manifold water tube (Fig. 13).

(8)Connect vacuum line to fuel pressure regulator.

(9)Remove covering on lower intake manifold and clean surface.