- Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-159248-S06644035342003112000000). Clean the fuel rail assembly and connections. Disconnect the fuel feed pipe and return pipe at the fuel rail. See «FUEL LINE DISCONNECT FITTINGS»(ref-159248-S39980982662003112000000).
- Disconnect the vacuum line from the fuel pressure regulator. Remove the ignition coil wires and retainer clips on top of the supercharger. Remove the rear generator mounting bracket with the purge valve attached. see scheme 39
- Remove the bypass valve actuator. Disconnect the fuel injector electrical connectors. Remove the fuel injector electrical harness clips holding harness to front and the rear of the fuel rail.
- Remove the fuel rail hold-down nuts. Remove the fuel rail with equal force on both sides of the fuel rail.
- To remove injector(s) from the fuel rail, remove the fuel injector retainer clip. Remove the fuel injector from the fuel rail. Remove and discard the fuel injector upper "O" ring.
| WARNING | 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. |
- Lubricate the new injector upper "O" ring seal with clean engine oil. Place the fuel rail assembly on the intake manifold. Seat the fuel injectors by HAND.
- Install the fuel rail hold-down nuts. Tighten the fuel rail hold-down nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159248-S05123880852003112000000).
- Install the bypass valve actuator. see scheme 29 Install the rear generator mounting bracket with the evaporative emission canister purge valve attached. see scheme 39 Connect the fuel injector electrical harness clips to the front of fuel rail.
- Connect the fuel injector electrical connectors to the fuel injectors. Install the ignition coil wires to the retainer clips on top of supercharger. Connect the vacuum line to the fuel pressure regulator. Connect the fuel feed, and return pipes to the fuel rail tubes.
- Tighten the fuel fill cap. Connect the negative battery cable. Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks. Install fuel sight shield.
