Fuel Rail: Service and Repair

Fuel Rail Assembly - Exploded View:

Engine Fuel Pipes:

Fuel Rail Removal:

Fuel Rail Assembly P/N Identification:

Removing the fuel rail assembly from the engine requires removing the top portion of the tuned intake manifold, called the "upper manifold assembly.
An eight digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.
Part names appear on the exploded view.

CAUTION:
^ Use care in removing the fuel rail assembly, to prevent damage to the injector electrical connector terminals and the injector spray tips.
^ Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped, and holes plugged, during servicing.
^ Before removal, the fuel rail assembly may be cleaned with a spray type cleaner, GM X-30A or equivalent, following package instructions. DO NOT soak fuel rails in liquid cleaning solvent.

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Service and Repair
3. Remove the upper manifold assembly.
4. Disconnect the fuel feed and return hoses from the engine fuel pipes.
5. Remove the O-ring seal from the engine fuel feed and return pipes, and discard.
6. Disconnect the vacuum line from the pressure regulator.
7. Remove the fuel rail retaining bolts.
8. Disconnect the injector electrical connectors.
9. Remove the fuel rail assembly.
10. Remove the injector O-ring seals from the tip of each injector and discard the seals.
11. Fuel rail removal does not require disconnecting the engine fuel pipes from the rail. However, if the fuel rail is being replaced, the fuel pipes must be replaced.

INSTALLATION:

1. Lubricate new injector O-ring seals with clean engine oil, and install on the spray tip end of each injector.
2. If the engine fuel pipes were disconnected from the fuel rail, reconnect them with new O-ring seals.
3. Install the fuel rail assembly in the intake manifold. Tilt the fuel rail assembly to install the injectors.

CAUTION: Use care in installing the fuel rail to prevent damage to the assembly. Apply pressure to the center portion of the rail to seat the injectors. DO NOT apply pressure to the regulator cover or fuel line connectors.

4. Install the fuel rail attaching bolts, and tighten to 10.0 Nm (88 lb.in).
5. Connect the injector electrical connectors.
6. Connect the vacuum line to the pressure regulator.
7. Install new O-ring seals on the engine fuel feed and return pipes.
8. Install the fuel feed and return hoses to the engine fuel pipes and tighten the nuts to 30 Nm (22 lb.ft).
9. Check for fuel leaks:
^ Temporarily connect the negative battery cable.
^ Turn the ignition switch to the ON position for two seconds, then turn it OFF for ten seconds. Again turn it ON and check for fuel leaks.
^ Disconnect the negative battery cable.
10. Install the upper manifold assembly.
11. Tighten the fuel filler cap.
12. Connect the negative battery cable.
13. The ECM will need to relearn the IAC valve position following battery reconnection.
a. Turn the ignition switch ON.
b. Ground the engine diagnostic lead for about five seconds.
c. START the engine and check for proper idle operation.