Fuel Injector and Fuel Rail Replacement. Geo Tracker - 2WD 1996

For 1990-2009 cars

### Removal Procedure

1. Remove the throttle body. Refer to Throttle Body Assembly Replacement .
2. Remove the Exhaust Gas Recirculation (EGR) pressure transducer (1) from the pressure transducer bracket (3).
3. Remove the two bolts (2) from the EGR pressure transducer bracket to the intake manifold.
4. Remove the EGR pressure transducer bracket (3) from the intake manifold.
5. Remove the two bolts (2) from the fuel pressure regulator to the fuel rail.
6. Remove the fuel pressure regulator (1) from the fuel rail.
7. Remove the fuel pulsation damper (1) from the fuel rail (2).
8. The fuel feed pipe from the fuel rail (2).
9. Disconnect the four fuel injector electrical connectors (1).
10. Remove the three bolts (4) from the fuel rail (3) to the intake manifold.
11. Remove the fuel rail (3) from the intake manifold.
12. Remove the four fuel injectors (2) from the intake manifold.

### Installation Procedure

Important: Always replace the fuel injector O-rings with new O-rings when servicing the fuel injectors, taking care not to damage the O-rings during installation.

1. Install the new O-rings (3) on the fuel injectors.
2. Install the grommets (2) to the fuel injectors.

Important: Inspect the insulators for breakage or scoring. If insulators are damaged, replace the insulator(s).

3. Install the three insulators (5) to the intake manifold.
4. Install the four cushions (4) to the intake manifold.
5. Apply a thin coat of fuel to the fuel injector O-rings and install the injectors (6) to the fuel rail (1).
6. Install the fuel rail (3) with injectors (2) to the intake manifold.

Important: Make sure that the fuel injectors rotate smoothly. check for an incorrectly install O-rings and replace with new O-rings

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.

7. Install the three bolts (4) to the fuel rail.

Tighten
Tighten the three fuel rail bolts to 18-28 N·m (13-20 lb ft).

Important: After securing the fuel rail make sure that the fuel injectors rotate smoothly.

8. Install the fuel feed pipe to the fuel rail.
9. Connect the four fuel injector electrical connectors (1).

Important: Apply a thin coat of engine oil to new gaskets

10. Install the fuel pulsation damper (1) and gaskets to the fuel rail (2).

Tighten
Tighten the fuel pulsation damper to 25-35 N·m (18.5-25 lb ft).

11. Install the fuel pressure regulator (1) to the fuel rail.
12. Secure the fuel pressure regulator to the fuel rail with two bolts (2).

Tighten
The fuel pressure regulator bolts to 8-12 N·m (6-8.5 lb ft).

13. Install the EGR pressure transducer bracket (3) to intake manifold.
14. Secure the EGR pressure transducer bracket with two bolts (2).

Tighten
Tighten the EGR pressure transducer bracket bolts to 23 N·m (17 lb ft).

15. Install the EGR pressure transducer (1) to the EGR pressure transducer bracket (3).
16. Install the throttle body. Refer to Throttle Body Replacement.