Pulsation Damper Replacement
10-08-2003, 03:59 PM
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Join Date: Sep 2002
Location: Tallahassee, FL
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(credit goes to i.didnt.do.it for the pics 
)
replacement parts:
the PD (in pic...detached from fuel rail)
gasket between upper intake manifold and lower intake manifold, and gasket sealant
recommended (inexpensive stuff, simple to replace, and can be bought at auto parts store):
injector o-rings (to ensure no fuel leaks there)
vacuum hoses (most likely the old ones are dry, brittle, and easily broken)
fuel hose, if any of your old fuel hose looks bad
Here's what I did:
(IF I HAVE ANYTHING WRONG, SOMEONE PLEASE CORRECT ME!!)
Look over the intake manifold, and get a good feel for what you're looking at, what you're going to remove, and what you have to disconnect to do it.
Depressurize the fuel system. To do so, find the electrical plug to the fuel pump. It is attached to the driver's side rear shock tower, under the carpet. Unplug it. Remove your gas cap. Start your car, and let it die. I think that's all there is to it, so gas won't spray when you remove your injectors or fuel hose.
Remove the intake hose and air filter. As I removed all the vacuum hoses, electrical connectors, etc., I labeled them. I didn't know what they were all for, so I just labeled them with numbers written on masking tape. Replace any vacuum lines that are old and brittle, or broken. Many of mine broke when I tried to remove them.
pic with everything but secondary injectors removed (stuff not labeled):
Pic of how the injector plugs come off (be sure not to break the plastic):
Remove the secondary fuel rail, which is right on top of your UIM (2 bolts). You don't have to disconnect the fuel lines for this, you can just kinda shove it out of the way. Your injectors should pull out with a twist. Label those, and set aside.
I believe there are 5 bolts holding the UIM to the LIM (second pic down...1 bolt, 4 nuts). On the driver's side of the intake manifold assembly, there are 5 bolts, for a support bracket (pic). I think there was a bolt holding onto the metal vacuum lines that run on the firewall side of the UIM, right near where the UIM meets the LIM. That one bolt pissed me off because it was kinda hidden. By now you should be able to lift the UIM/throttle body off the LIM.
Put some paper towels or rags in the LIM, so you don't end up dropping crap in the engine (pic). Remove the old gasket from the UIM and/or LIM. Your PD and primary fuel rail should be easily accessible by now. Remove your primary fuel rail and injectors (2 bolts), being sure to label them (don't mix up your primaries and secondaries). My new PD was attached to a new fuel rail, but I think you can remove with a wrench.
Look in that messy area under the UIM that you removed. Replace any vacuum hoses that need to be replaced. DON'T TOUCH YOUR OIL METERING LINES IF YOU CAN HELP IT. Mine broke on contact, and they're not cheap to replace. But do inspect them, to be sure they're not leaking oil, and replace broken lines. Replace any fuel lines that need to be replaced. Replace your fuel injector o-rings. Clean up any fuel, oil, or grime. You never know how flammable that stuff is until your car is a heap of ashes.
Use your new gasket, with some gasket sealant. Replace everything, reverse of removal. Since you labeled everything, it should be simple to see if you left anything off. Check all vacuum hoses to be sure everything's in place. One loose vacuum hose can make your car run badly. Be sure that your fuel pump is plugged back in. It may take awhile to start, as fuel is primed into the system.
Check for fuel leaks!!!!
replacement parts:
the PD (in pic...detached from fuel rail)
gasket between upper intake manifold and lower intake manifold, and gasket sealant
recommended (inexpensive stuff, simple to replace, and can be bought at auto parts store):
injector o-rings (to ensure no fuel leaks there)
vacuum hoses (most likely the old ones are dry, brittle, and easily broken)
fuel hose, if any of your old fuel hose looks bad
Here's what I did:
(IF I HAVE ANYTHING WRONG, SOMEONE PLEASE CORRECT ME!!)
Look over the intake manifold, and get a good feel for what you're looking at, what you're going to remove, and what you have to disconnect to do it.
Depressurize the fuel system. To do so, find the electrical plug to the fuel pump. It is attached to the driver's side rear shock tower, under the carpet. Unplug it. Remove your gas cap. Start your car, and let it die. I think that's all there is to it, so gas won't spray when you remove your injectors or fuel hose.
Remove the intake hose and air filter. As I removed all the vacuum hoses, electrical connectors, etc., I labeled them. I didn't know what they were all for, so I just labeled them with numbers written on masking tape. Replace any vacuum lines that are old and brittle, or broken. Many of mine broke when I tried to remove them.
pic with everything but secondary injectors removed (stuff not labeled):
Pic of how the injector plugs come off (be sure not to break the plastic):
Remove the secondary fuel rail, which is right on top of your UIM (2 bolts). You don't have to disconnect the fuel lines for this, you can just kinda shove it out of the way. Your injectors should pull out with a twist. Label those, and set aside.
I believe there are 5 bolts holding the UIM to the LIM (second pic down...1 bolt, 4 nuts). On the driver's side of the intake manifold assembly, there are 5 bolts, for a support bracket (pic). I think there was a bolt holding onto the metal vacuum lines that run on the firewall side of the UIM, right near where the UIM meets the LIM. That one bolt pissed me off because it was kinda hidden. By now you should be able to lift the UIM/throttle body off the LIM.
Put some paper towels or rags in the LIM, so you don't end up dropping crap in the engine (pic). Remove the old gasket from the UIM and/or LIM. Your PD and primary fuel rail should be easily accessible by now. Remove your primary fuel rail and injectors (2 bolts), being sure to label them (don't mix up your primaries and secondaries). My new PD was attached to a new fuel rail, but I think you can remove with a wrench.
Look in that messy area under the UIM that you removed. Replace any vacuum hoses that need to be replaced. DON'T TOUCH YOUR OIL METERING LINES IF YOU CAN HELP IT. Mine broke on contact, and they're not cheap to replace. But do inspect them, to be sure they're not leaking oil, and replace broken lines. Replace any fuel lines that need to be replaced. Replace your fuel injector o-rings. Clean up any fuel, oil, or grime. You never know how flammable that stuff is until your car is a heap of ashes.
Use your new gasket, with some gasket sealant. Replace everything, reverse of removal. Since you labeled everything, it should be simple to see if you left anything off. Check all vacuum hoses to be sure everything's in place. One loose vacuum hose can make your car run badly. Be sure that your fuel pump is plugged back in. It may take awhile to start, as fuel is primed into the system.
Check for fuel leaks!!!!
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