Caution! Gasoline is extremely flammable, so exercise extreme caution when working around the fuel system (see paragraph 2).
Removal
1. Relieve the pressure in the fuel system (see paragraph 2).
2. Disconnect the ground cable from the negative battery terminal.
Models produced before 2000
3. Remove the valve cover (see Chapter 2A).
4. Remove the throttle body (see paragraph 14).
5. Remove the two fasteners and disconnect the wiring harness from the intake manifold housing (see Figure 16.5).
Figure 16.5. Exploded view of fuel rail and surrounding components - pre-2000 models.
Disconnect the wiring connectors from all four injectors.
6. Remove the engine wiring harness protective covers from the right side of the intake manifold.
7. Remove the EGR valve and its tube (see Chapter 6A).
8. Disconnect the upper fitting on the fuel filter (see Chapter 1A) and separate the fuel line from the filter.
9. Disconnect the brake booster vacuum hose from the intake manifold.
10. Disconnect the fuel lines from the fuel rail (see Figure 16.10).
Figure 16.10. Disconnect the fuel lines from the fuel rail.
11. Loosen the fuel rail mounting bolts (see Figure 16.11).
Figure 16.11. Loosen the fuel rail mounting bolts (shown by arrows).
12. Remove the injectors from the fuel rail (see Figure 16.12) and place them in labeled boxes or bags.
Figure 16.12. Remove the injector from the fuel rail by twisting it.
13. If you are going to install the same injectors, replace the sealing rings and rubber bushings on them.
Figure 16.13. If you plan to reinstall the removed injectors, replace the sealing rings and rubber bushings.
Models produced since 2001
14. Remove the air filter housing (see paragraph 10).
15. Disconnect the positive crankcase ventilation valve hose (see Chapter 6A).
16. Disconnect the fuel lines from the fuel rail (see figure 16.16,a,b).
Figure 16.16,a. Release the wiring harness from the clips on the intake manifold housing.
Figure 16.16b. Exploded view of the fuel rail and surrounding components of the 2001 and later models.
17. Loosen the fuel rail mounting bolts (see figure 16.17).
Figure 16.17. Loosen the fuel rail mounting bolts (shown by arrows).
18. Remove the fuel rail without disconnecting the injectors.
19. Remove the injector(s) from the fuel rail (see figure 16.19) and put them in labeled boxes or bags.
Figure 16.19. Be sure to install new O-rings and rubber bushings on the injectors and fuel pressure regulator.
20. If you are going to install the same injectors, replace the sealing rings and rubber bushings on them.
Installation
21. Installation of injectors is carried out in the reverse order of their removal.
22. Tighten the injector mounting bolts to the specified torque Specifications.