Fuel Injector Manifold Assembly

Fuel Rail Assembly:

REMOVAL

1. Remove throttle body assembly.
a. Disconnect negative battery cable.
b. Loosen air cleaner duct hose retaining clamps and remove hose.
c. Remove Idle Air Control (IAC) solenoid shield.
d. Disconnect throttle cable and TV cable from throttle body linkage.
e. Mark location and remove vacuum hoses at vacuum tree.
f. Loosen EGR tube nuts if equipped at EGR valve and exhaust manifold fitting. Remove or rotate tube out of the way.
g. Remove PCV hose from the tube underneath throttle body.
h. Disconnect electrical connections to Intake Air Temperature (IAT), IAC and Throttle Position (TP) sensor.
i. Remove retaining nuts from generator brace and remove brace.
j. Loosen and remove the six throttle body retaining bolts (note location to be used for installation).
k. Lift and remove throttle body assembly from intake manifold.
2. Scribe an alignment mark on the base of the distributor and the intake manifold. Remove distributor hold-down clamp and lift distributor for clearance when removing manifold.
3. Disconnect the fuel supply and return lines.
4. Carefully disconnect wiring harness from fuel injectors.
5. Disconnect vacuum line from the fuel pressure regulator.
6. Remove four fuel injector supply manifold retaining bolts.
7. Carefully disengage fuel injection supply manifold assembly from fuel injectors by lifting and gently rocking the rail.
8. Remove fuel injectors by lifting while gently rocking side to side.
9. Place removed components in clean container to avoid dirt or other contamination.

INSTALLATION
1. Examine injector O-ring for deterioration. Install new O-rings if required.
2. Lubricate new O-ring and install two on each injector using clean engine oil.
3. Ensure injector cups are clean and free of contamination or damage.
4. Install fuel injectors in fuel injector supply manifold using light twisting-pushing motion.
5. Prior to installation of manifold perform the following:
a. Lift the distributor enough to allow fuel injection manifold crossover tube to clear.
b. Lower distributor into position.
c. Install distributor hold-down clamp and align scribe marks.
6. Carefully install fuel injection supply manifold assembly and fuel injectors into lower intake manifold, one side at a time. To ensure that O-rings are seated, push down on fuel injection supply manifold.
7. While holding fuel injection supply manifold assembly in place, install two retaining bolts.
8. Connect spring lock coupling fuel supply (1/2 in.) and fuel return (3/8 in.) lines.
9. Before connecting the fuel charging wiring harness, turn the ignition switch ON position several times. this will pressurize the fuel system.
10. Using a clean paper towel, check for leaks where the fuel injectors connect to the fuel injection supply manifold.
11. connect the fuel charging wiring harness to fuel injectors.
12. Clean and inspect sealing surfaces of intake manifold to throttle body.
13. Place gasket on intake manifold.
14. Align bolt holes and install throttle body on intake manifold. Install one stud and five retaining bolts.
15. Install generator brace to throttle body and generator bracket.
16. Connect PCV hose to tube underneath throttle body.
17. Install EGR tube to EGR valve and exhaust manifold, if equipped.
18. Connect vacuum lines to their pre-marked locations.
19. Connect electrical connections to IAT sensor, IAC valve and TP sensor.
20. Connect throttle and TV cables to throttle body linkage.
21. Connect air cleaner outlet tube to throttle body and air cleaner assembly.
22. Connect negative battery cable.
23. Start engine and check for vacuum leaks.
24. Check engine idle. Adjust as necessary.
25. Adjust TV cable.
26. Install shield onto idle air control valve.