Fuel Rail Replacement

Fuel Rail Assembly - Exploded View:

Fuel Rail Identification:

Fuel Rail And Injectors:

FUEL RAIL REMOVAL:

Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner, such as AC-Delco X-30A or equivalent.

CAUTION:
^ DO NOT immerse fuel rails in liquid cleaning solvents.
^ When servicing the fuel rail assembly, be careful to prevent dirt or other contaminants from entering the fuel passages. Fittings should be capped and holes should be plugged during servicing.
^ Whenever the fuel system is opened for service, the O-ring seals used with related components should be replaced.
^ Support the fuel rail to avoid damaging components.

1. Disconnect the negative battery cable.
2. Remove the air cleaner.
3. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
4. Move the power steering pump.
5. Disconnect the vacuum line from the pressure regulator and base assembly.
6. Disconnect the accelerator cable, cruise control cable and bracket.
7. Disconnect the electrical connectors from the TPS, ISC, CTS and MAT sensors.
8. Remove the coolant hose to thermostat housing.
9. Disconnect the fuel feed line from the rear fuel rail assembly. Discard the O-ring.
10. Disconnect the fuel return line. Discard the O-ring.

IMPORTANT: Wrap a shop towel around fuel lines to collect fuel. Place cloth in an approved container.

11. Disconnect the EGR vacuum lines from the EGR valve.
12. Remove the five rail support bracket bolts.
13. Disconnect the electrical connectors at the front and rear fuel rail assemblies.
14. Remove the fuel rail assembly from the intake manifold.

FUEL RAIL INSTALLATION:

NOTE: Lubricate new injector O-ring seals with clean engine oil, and install on the fuel injector tips.

1. Install the fuel rail assembly to the intake manifold.
2. Install the five rail support bracket bolts, and tighten to 24 N-m (18 lb. ft.).
3. Connect the electrical connector at the front and rear fuel rail assemblies.
4. Install the EGR valve and vacuum lines.
5. Connect the fuel feed line. Use a new O-ring. Lubricate the O-ring with a petroleum based grease before installation.
6. Connect the fuel return line. Use a new O-ring. Lubricate the O-ring with a petroleum based grease before installation, and ising a back-up wrench to prevent damage, tighten both the fuel feed and return lines to 30 N-m (22 lb. ft.).
7. Connect the coolant hose to the thermostat housing.
8. Connect the electrical connectors to the TPS, ISC, coolant and MAT sensors.
9. Connect the accelerator cable, cruise control cable, and bracket.
10. Connect the vacuum line to pressure regulator and base assembly.
11. Install the power steering pump.
12. Install the air cleaner.
13. Connect the negative battery cable.
14. Energize the fuel pump and check for fuel leaks.
15. Perform the IDLE LEARN PROCEDURE, refer to MAINTENANCE PROCEDURES/IDLE LEARN PROCEDURES.