Release the fuel system pressure and disconnect the negative battery cable.
Disconnect the air, vacuum and water hoses from the throttle body and air
funnel. Plug the water hoses to prevent leakage.
Loosen the hose clamps and remove the air funnel.
Disconnect the Bypass Air Control (BAC) valve connector and water hoses,
then remove the valve.
Detach the throttle sensor connector and the accelerator cable. Remove the
throttle body and gasket. Disconnect all vacuum hoses, EGR pipe, EGR position
sensor connector, water hose and ground wire.
Remove the wiring harness bracket. Disconnect the air intake pipe from the
dynamic chamber with the gasket. Mark the extension manifolds RIGHT and LEFT
for assembly reference, as they are not interchangeable. Remove the six extension
manifolds with their gaskets from the dynamic chamber.
Disconnect the intake air thermo sensor connector, vacuum hoses and ground
connectors. Remove the attaching nuts and lift the dynamic chamber straight
up from the intake manifold studs.
Detach the injector electrical connectors and the fuel hoses from the pressure
regulator, then cover the high pressure fuel connections with a rag. Unfasten
the banjo connector from the top of the fuel distribution pipe, and the high
pressure fuel line from the bottom of the fuel pressure regulator. Repeat
this procedure for the fuel rail on the other side.
Remove the two mounting bolts from the underside of the fuel distribution
pipe. Gently pull the assembly away from the intake manifold so the injectors
and seals slide out of their recesses in the manifold. Pull the injectors
and seals out of the distribution pipe.
Installation is essentially the reverse of the removal procedure. Coat the
injector O-rings with clean engine oil prior to installation. When inserting
the injectors into the distribution pipe, make sure that they are installed
straight and not cocked, or fuel leakage will result.
Reattach all the injector connectors securely. The injector connectors are
color coded black and white. The No. 1, No. 3 and No. 5 connectors are black,
and the No. 2, No. 4. and No. 6 connectors are white (see illustration).
After installation, jumper the fuel pump connector, as described under the
fuel pump testing procedures, and check for injector leaks. Make repairs as
necessary, before operating the engine. Check for water leaks also.
