D. Assemble and Install Fuel Rail
1. Clean the fuel rail, intake manifold intake plenum and EGR tube gasket surfaces.CAUTION:
DO NOT use metal scrapers, grinding discs or abrasives to clean aluminum components as damage to sealing surfaces may occur.
2. Lightly lubricate the supplied fuel pressure regulator 0-rings with clean engine oil.
NOTE:
The pressure regulator O-rings are sealed together in one of the O-ring kit bags.
3. Install the large diameter O-ring into the fuel rail pressure regulator pocket. Use a socket or similar tool to ensure that the O-ring is properly seated.
4. Install the small diameter pressure regulator O-ring into the outlet rail pocket. Use a socket or similar tool to ensure that the O-ring is properly seated.
5. install the original fuel pressure regulator into the outlet rail and "seat" it into the O-rings.
6. Lightly lubricate the O-rings on the provided crossover plugs with clean engine oil (Figure 9).
NOTICE:
The crossover plug 0-rings should already be installed on the crossover plugs.
7. Install one of the supplied crossover plugs into the inlet rail (Figure 9).
8. Install the other crossover plug into the outlet rail (Figure 9).
9. Lightly lubricate the supplied outlet tube 0-ring with clean engine oil and install it onto the outlet tube (Figure 9).
IMPORTANT:
The outlet tube 0-ring is the small 0-ring that is sealed in one of the 0-ring kit bags with 3 larger 0-rings. Use the 0-ring template in the kit to insure that the proper 0-ring is installed in this location.
10. Install the outlet tube into the outlet rail and then install the outlet tube clip onto the outlet rail (Figure 9).
11. Using one of the supplied gaskets, install the outlet fuel rail onto the engine.
12. Lightly lubricate the supplied inlet tube O-ring with clean engine oil and install it onto the inlet tube (Figure 9).
13. Install the inlet tube into the inlet rail and then install the inlet tube clip onto the inlet rail (Figure 9).
14. Using the other supplied gasket, install the inlet fuel rail onto the engine.
15. Lightly lubricate the remaining two supplied crossover tube 0-rings with clean engine oil (Figure 9).
16. Install one of the 0-rings onto each end of the crossover tube (Figure 9).
17. Install the crossover tube into the inlet and outlet rails (Figure 9). Secure the tube by installing the crossover tube clips.
18. Install the inlet rail retainer and then slide the retainer toward the rear of the inlet rail (Figure 9).
19. Remove the four (4) tie straps from the outlet rail reinforcements (if applicable).
20. Install the outlet rail retainer and then slide the retainer toward the front of the outlet rail (Figure 9).
21. Install the inlet and outlet rail retainer screws (Figure 9). Tighten the screws to 15 in-lbs (1.7 N.m).
22. Install the six (6) fuel rail mounting bolts (Figure 9). Tighten the fuel rail mounting bolts to 100 in-lbs (11 N.m).
23. Install the fuel tube support bracket bolt (Figure 9).
24. Connect the negative battery cable.
25. Using the DRB III, pressurize the fuel system and check for leaks.
26. Connect the fuel pressure regulator vacuum hose.
27. Connect the injector electrical connectors.
28. Connect the coolant temperature sensor electrical connector.
29. Uncover the intake manifold openings and, using the supplied gasket, install the intake plenum. Tighten the mounting bolts to 250 in-lbs (28 N.m) in the sequence shown in Figure 12.
30. Install the air intake plenum support bracket bolt on each side of the manifold (Figure 6). Tighten the bolts to 250 in-lbs (28 N.m).
31. Connect the EGR tube to the intake plenum (Figure 5) as follows:
a. Loosely install the EGR tube using the supplied gaskets.
b. Tighten the EGR tube screws to 200 in-lbs (22 N.m).
c. Ensure that the insulation on the EGR tube aligns with and contacts the insulation on the vacuum harness at the rear of the engine.
32. Connect the [1][2]PCV hose, brake booster hose and other vacuum hoses to the intake plenum.
33. Connect the purge hoses to both throttle bodies (Figure 4).
34. Connect the TPS electrical connector (Figure 4).
35. Connect the MAP sensor electrical connector (Figure 3).
36. Connect the vacuum hose to the MTV (Figure 2).
37. Connect the IAC and intake air temperature sensor electrical connectors (Figure 2).
38. Install the throttle cable and speed control cable into the mounting bracket (Figure 1).
39. Hold the throttle lever in the wide-open position and install the throttle cable and speed control cable into the lever (Figure 1).
40. Install the engine cover to the top of the intake manifold plenum.
41. Install the air inlet plenum behind the manifold and connect the [1][2]PCV makeup air hose and IAC supply hose (part of the air inlet plenum).
42. Install the air inlet tube between the air cleaner and the inlet plenum.