For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 37088-A Fuel Line Quick-Connect Separator Tool Set

Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

Important: Always maintain cleanliness when servicing fuel system components.

1. Bleed fuel pressure from the fuel system. Refer to Fuel Pressure Relief .
2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed and fuel return pipes from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .
4. Remove the fuel injector coil wires.
5. Remove the vacuum line from the vacuum source to the fuel pressure regulator.
6. Remove the MAP sensor electrical connector.
7. Remove the vacuum line to the vacuum switch from the fuel pipe bundle.
8. Remove the vacuum source from the intake manifold.
9. Remove the fuel injector electrical connectors.
10. Remove the fuel injector harness fasteners.
11. Remove the fuel rail hold-down bolts.
12. Remove the fuel rail with equal force on both sides of the fuel rail.
13. Remove the front fuel injector retaining clips on each side of the fuel rail.
14. Remove the front fuel injector on each side of the fuel rail. The fuel rail will now clear the intake manifold.

### Installation Procedure

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

Notice:

• | Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.

• | Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.

• | Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

1. The O-rings must be replaced on all components that are replaced.
2. Lightly oil the fuel injector O-rings with clean engine oil.
3. Place the fuel rail assembly (WITHOUT the front fuel injectors on each side of the fuel rail) on the intake manifold.
4. Reinstall the front fuel injector on each side of the fuel rail.
5. Reinstall the fuel injector retaining clips on the front fuel injector on each side of the fuel rail.
6. Seat the fuel injectors by HAND.

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.

Tighten
Tighten the fuel rail hold-down bolts to 10 N·m (89 lb in).

7. Reconnect the fuel injector harness fasteners.
8. Reconnect the fuel injector electrical connectors.
9. Reinstall the vacuum source to the intake manifold.
10. Reinstall the vacuum line to the vacuum switch from the fuel pipe bundle.
11. Reinstall the vacuum line from the vacuum source to the fuel pressure regulator.
12. Reconnect the fuel feed and fuel return pipes by pushing the pipes onto the fuel rail tubes.
13. Reconnect the MAP sensor electrical connector.
14. Reconnect the fuel injector coil wires.
15. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in engine electrical.
16. Inspect for leaks.

16.1. | Turn the ignition switch ON for 2 seconds.

16.2. | Turn the ignition switch OFF for 10 seconds.

16.3. | Turn the ignition switch ON.

16.4. | Check for fuel leaks.