C. Replace Fuel Rail Assembly
NOTE:Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail replacement.
WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before replacing the fuel rail.
1. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.
3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6).
WARNING:
Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when pressure is released from the rail.
4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure.
5. Remove the hose from the fuel rail and reinstall the test port cap.
6. Remove the plastic intake manifold cover, if equipped.
7. Remove the air inlet resonator.
8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and bracket (Figure 7).
9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Figure 8).
10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9).
11. Disconnect the EGR tube from the intake manifold flange (Figure 10).
12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head.
13. Disconnect the MAP sensor electrical connector (Figure 11).
14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12).
WARNING:
Wrap a shop towel around the hoses to catch any gasoline spillage.
15. Remove the Direct Ignition System (DIS) coil pack (Figure 13).
16. Remove the generator support bracket.
17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve cover (Figure 14).
NOTE:
It is not necessary to completely remove the intake plenum from the vehicle.
18. Cover the intake manifold openings.
19. Remove the fuel rail attaching bolts (Figure 15).
20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16).
21. Disconnect the fuel rail wiring harness from the main engine harness.
22. Remove the fuel rail assembly.
23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors are easily accessible.
24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring harness from the fuel rail.
25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the injector (Figure 17).
26. Remove the upper and lower injector 0-rings from the injectors.
27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil.
28. Install the new upper 0-rings (BLUE) on the top of the injectors.
CAUTION:
Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result.
29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil.
30. Install the new lower 0-rings (BLACK) on the bottom of the injectors.
31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot of the injector.
32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully seated. Use care so that the upper 0-ring is not damaged during installation.
33. Connect the injector wiring harness to the injectors.
34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail assembly into place until all injectors are seated in their port.
35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22 N.m).
36. Connect the fuel injector wiring harness to the main engine wiring harness.
37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the connector on until it clicks and then pull back to ensure a complete connection.
38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16).
39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake plenum gasket surfaces.
40. Place the provided intake plenum gasket on the intake manifold.
41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum bolts. Do NOT tighten.
42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten.
43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT tighten.
44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely install the mounting bolts. Do NOT tighten.
45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28 N.m).
46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m).
47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m).
48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10).
49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm).
50. Connect the MAP sensor electrical connector (Figure 11).
51. Connect the vacuum hoses to the intake plenum (Figure 9).
52. Connect the TPS and idle air control motor electrical connectors (Figure 8).
53. Connect the throttle body vacuum connectors (Figure 9).
54. Connect the throttle cable and speed control cable (if equipped) (Figure 7).
55. Install the intake manifold cover (if equipped).
56. Install the air inlet resonator.
57. Connect the negative battery cable.
58. Start the engine and check for any fuel leakage.