For 1990-2009 cars

## Fuel Injection Fuel Rail Assembly Replacement w/o EGR

### Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
4. Remove the vacuum hose at the fuel pressure regulator.
5. Remove the camshaft position (CMP) sensor connector.
6. Remove the retaining clips for the fuel injector connector .
7. Remove the injector connectors (1).
8. Remove the fuel inlet pipe at the fuel rail. Use a backup wrench on the fuel rail inlet fitting to prevent the fitting from turning.
9. Remove the fuel pipe retainer clip nut, if equipped.
10. Remove the fuel pipe retainer clip bolt.
11. Remove the fuel rail attaching bolts (1).
12. Lift the fuel rail assembly (1) from the cylinder head.
13. Loosen the attaching screw (3) for the fuel return pipe bracket . Rotate the retaining bracket (4) to allow the fuel pipe to be removed.
14. Remove the fuel return pipe (2) from the fuel pressure regulator (1).
15. Remove the inlet and the return pipe assemblies. Discard the O-ring (5).
16. Remove the fuel rail assembly.

### Installation Procedure

1. Apply a few drops of clean engine oil to the male end of the fuel pipes before installing the fuel rail assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: Whenever there is not enough thread-locking material on the threads of the fuel outlet pipe bracket screw, apply Loctite® 262 to ensure proper locking.

2. Install the fuel return pipe (2) into the fuel pressure regulator (1). Align the bracket (4) in order to retain the return pipe).

Tighten
Tighten the bracket screw to 6.0 N·m (53 lb in).

Important: Use a backup wrench on the fuel rail inlet fitting to prevent the fitting from turning.

3. Install the fuel rail inlet fitting to the fuel rail assembly.

Tighten
Tighten the fitting to 30 N·m (22 lb ft)

4. Install the fuel pipe retainer clip nut, if equipped.

Tighten
Tighten the retainer clip nut to 12 N·m(106 lb in).

5. Install the bolt to the fuel pipe retainer clip .

Tighten
Tighten the bolt to 12 N·m(106 lb in).

Important: Lubricate fuel injectors O-rings with clean engine oil before installation.

6. Install the fuel rail assembly (1) into the cylinder head.
7. Install the fuel rail assembly attaching bolts (1).

Tighten
Tighten the attaching bolts to 26 N·m (19 lb ft).

8. Install the fuel injector connectors (1).
9. Install the retaining clips for the fuel injector connectors .
10. Connect the camshaft position sensor.
11. Install the vacuum hose to the fuel pressure regulator.
12. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
13. Reconnect the negative battery cable.
14. Use the following procedure in order to inspect for fuel leaks:

14.1. | Turn on the ignition for 2 seconds, leaving the engine off .

14.2. | Turn off the ignition for 10 seconds.

14.3. | Turn on the ignition, leaving the engine off.

14.4. | Inspect for fuel leaks.