A. Leak Test and Remove the Fuel Rail
1. Remove the air inlet hose between the air cleaner and inlet plenum.2. Disconnect the [1][2]PCV makeup air hose and idle air control (IAC) supply hose (part of the air inlet plenum) then disconnect the air inlet plenum from the throttle bodies and set it aside. Do not remove the inlet plenum from behind the manifold.
3. Remove the engine cover from the top of the intake manifold plenum.
4. Hold the throttle lever in the wide-open position and remove the throttle cable and speed control cable from the lever (Figure 1).
5. Remove the throttle cable and speed control cable from their mounting bracket by compressing the locking tabs (Figure 1).
6. Disconnect the IAC and intake air temperature sensor electrical connectors (Figure 2).
7. Disconnect the vacuum hose from the [1][2]manifold tuning valve (MTV) (Figure 2).
8. Disconnect the MAP sensor electrical connector (Figure 3).
9. Disconnect the Throttle Position Sensor (TPS) electrical connector (Figure 4).
10. Disconnect the purge hose from both of the throttle bodies (Figure 4).
11. Disconnect the [1][2]PCV hose, brake booster hose and other vacuum hoses from the intake plenum.
12. Disconnect the EGR tubes from the intake plenum (Figure 5). Discard the gaskets.
13. Remove the intake plenum support bracket bolt on each side of the plenum (Figure 6).
14. Remove the intake plenum mounting bolts then lift the plenum up and off the engine. Discard the gasket.
15. Cover the intake manifold openings to prevent foreign material from entering the engine. Then, using shop air, clean any loose dirt and debris from around the fuel injectors.
16. Tag the injector electrical connectors to identify their location then disconnect the injector electrical connectors.
17. Using the DRB III, pressurize the fuel system.
18. Inspect the outside of the outlet fuel rail for fuel leakage and/or cracks near the # 3 and # 5 injector ports.
19. With the ignition key in the OFF position, disconnect the battery.
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.
20. Remove the fuel tank filler cap to release the fuel tank pressure.
WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before servicing the fuel rail.
21. Remove the protective cap from the pressure test port on the fuel rail (Figure 8).
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.
22. Obtain the hose from the fuel pressure gauge tool set 4C-4799-A. 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.
23. Remove the hose from the fuel rail and reinstall the test port cap.
24. Disconnect the fuel pressure regulator vacuum hose.
25. Disconnect the coolant temperature sensor electrical connector.
26. Remove the six (6) fuel rail mounting bolts (Figure 9).
27. Remove the inlet and outlet rail retainer screws (Figure 9).
28. Slide the inlet rail retainer toward the front of the inlet rail and lift retainer off rail (Figure 9).
29. Slide the outlet rail retainer toward the rear of the outlet rail and lift retainer off rail (Figure 9).
30. Remove the fuel tube support bracket bolt (Figure 9).
NOTE:
Do not remove the bracket bolt from the intake manifold (shared with heater hose nipple) as coolant leaks may occur.
31. Tag and remove the inlet tube clip from the inlet rail then pull rearward to disconnect the inlet tube from the inlet rail (Figure 9).
NOTE:
Do NOT disconnect the inlet tube from the fuel supply hose quick connect.
CAUTION:
Inlet and outlet tube clips are not interchangeable.
32. Remove and discard the inlet tube O-ring.
33. Tag and remove the outlet tube clip from the outlet rail then pull rearward to disconnect the outlet tube from the outlet rail (Figure 9).
NOTE:
Do NOT disconnect the outlet tube from the fuel return hose quick connect.
CAUTION:
Inlet and outlet tube clips are not interchangeable.
34. Remove and discard the outlet tube 0-ring.
35. Remove the crossover tube clips from the inlet and outlet rails (Figure 9).
36. Remove the crossover tube from the inlet and outlet rails (Figure 9). Discard the crossover tube O-rings.
37. Remove the inlet and outlet fuel rails from the engine (Figure 9).
38. Thread a 5/16" slide hammer or Miller Special # C-3752 into the inlet rail crossover plug and then remove the crossover plug (Figure 9). Discard the plug and 0-ring.
NOTE:
The crossover plug is not threaded. Threads must be cut into the plastic plug with the tool.
39. Thread the slide hammer or Miller Tool into the outlet rail crossover plug and then remove the crossover plug (Figure 9). Discard the plug and 0-ring.
40. Remove the fuel pressure regulator from the outlet rail (Figure 9).
41. Remove and discard the pressure regulator 0-rings.
42. ^ If the outlet rail did NOT leak in Step 18, the outlet rail must be reinforced. Proceed to the service procedure in Section "B" to reinforce the outlet rail.
^ If the outlet rail leaked fuel in Step 18, the outlet rail must be replaced. Proceed to the service procedure in Section "C" to replace the outlet rail.