Fuel Rail: Service and Repair

Fuel Rail Assembly Model R630:

Fuel Rail Identification:

Fuel Rail Removal:

An eight digit identification number is stamped on the under side of the fuel rail. Refer to this number if servicing or part replacement is required.

WARNING: To reduce the risk of fire and personal injury, disconnect the negative battery cable before servicing the fuel rail assembly.

CAUTION:
^ The fuel inlet fitting is staked in place on the fuel rail. DO NOT try to remove it. To do so will result in damage to the fuel rail or to the internal O-ring seal.
^ Use care in removing the fuel rail assembly, to prevent damage to the injector electrical connector terminals and spray tips.
^ Prevent dirt and other contaminates from entering open lines and passages. Fittings should be capped, and hoses plugged, during service.
^ Before removal, the rail assembly may be cleaned with a spray cleaner, GM X-30A or equivalent, following package instructions. DO NOT immerse the fuel rail in liquid cleaning solvent.

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Disconnect the injector electrical connectors.
4. Disconnect the vacuum hose from the fuel pressure regulator.
5. Disconnect the fuel feed and return pipes.
^ Use a back-up wrench on the fuel inlet fitting to prevent it from turning.
6. Remove the O-ring seals from the pipes and discard.
7. Remove the fuel attaching nuts.
8. Remove the fuel rail assembly.
9. Remove the O-ring seals from the spray tip end of each injector, and discard.

INSTALLATION:

1. Lubricate new injector O-ring seals with clean engine oil and install on each injector.
2. Position the fuel rail assembly on the intake manifold. Push down on the rail to seat the injectors in the manifold.
3. Install the fuel rail attaching nuts, and tighten to 27 Nm (20 lb.ft).
4. Install new O-ring seals on the fuel pipes.
5. Connect the fuel feed and return pipes.
^ Use a back-up wrench on the fuel rail inlet fitting to prevent it from turning.
6. Connect the vacuum hose to the regulator.
7. Connect the injector electrical connectors.
8. Tighten the fuel filler cap.
9. Connect the negative battery cable.
10. Turn the ignition switch to the ON position for two seconds, then turn it to the OFF position for ten seconds. Again turn the ignition switch to the ON position and check for fuel leaks.