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Fuel Injectors & Fuel Rails: Removal

  1. Disconnect negative battery cable. Drain engine coolant. Disconnect cruise control actuator, accelerator and throttle cables. Label and disconnect emission control hoses.
  2. Remove EGR valve, vacuum modulator and EGR pipe by loosening 2 union nuts and removing mounting clamp. Release fuel pressure at filter. See FUEL SYSTEM PRESSURE RELEASE. Remove bolt holding heater inlet pipe and air intake chamber.
  3. Disconnect air cleaner hose, No. 1 and 2 PCV hoses, vacuum hoses, No. 2 coolant by-pass hose, and EVAP and brake booster hoses. Disconnect throttle position sensor, idle air control valve and emission control valve assembly connectors.
  4. Disconnect power steering reservoir tank, and remove engine oil dipstick and guide. Disconnect engine wiring harness connectors around intake manifold area. Disconnect Thermal Vacuum Valve (TVV) vacuum hoses and No. 1 coolant by-pass hose. Remove 4 nuts and bolts, 2 gaskets and air intake chamber. Remove fuel return hose and No. 1 fuel pipe.
  5. Disconnect injector connectors. Remove wiring harness from area. Label and disconnect fuel and vacuum hoses. Remove 3 bolts, and remove fuel rail with 6 injectors attached. Remove 6 insulators and 3 spacers from intake manifold. Pull injectors from fuel rail. Remove "O" rings and grommets from injectors. See Figure.
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