Fuel Rail: Service and Repair
REMOVAL PROCEDUREAn eight digit identification number is located on the fuel rail assembly. Refer to this model identification number if servicing or pant replacement is required.
CAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Remove the upper intake manifold.
4. Remove the distributor.
5. Before removal, clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak fuel rails in liquid cleaning solvent.
NOTE:
^ Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
6. Disconnect the fuel feed and return pipes at the fuel rail.
7. Disconnect the injector harness electrical connector.
8. Disconnect the fuel pressure regulator vacuum hose from the intake manifold fitting.
9. Remove the fuel rail stud (1) and bolts (2), (3).
10. Remove the fuel rail from the intake manifold.
11. Remove the fuel teed and return pipe O-rings and discard.
12. Remove the injector electrical harness from the fuel rail.
13. Remove the injector O-ring seal from the spray tip end of each injector. Discard the seals. With the O-ring removed, the O-ring backup may slip off of the injector. Be sure to retain O-ring backup for reuse.
INSTALLATION PROCEDURE
1. Install the injector electrical harness on the fuel rail.
2. Lubricate the new lower injector O-ring seals with clean engine oil.
IMPORTANT: Ensure that the O-ring backups are on the injectors before installing the new O-rings.
3. Install the new O-ring seals on the spray tip end of each injector.
4. Install the new fuel feed and return pipe O-ring seals.
5. Install the fuel rail assembly in the intake manifold. Tilt the rail assembly to install the injectors.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Install the fuel rail stud (1) and bolts (2), (3).
Tighten
^ Tighten the fuel rail stud (1) to 25 N.m (18 lb ft).
^ Tighten the fuel rail bolts (2), (3) to 10 N.m (89 lb in).
7. Connect the fuel pressure regulator vacuum hose to the intake manifold fitting.
8. Connect the injector harness electrical connector.
9. Connect the fuel feed and return pipes.
Tighten
Use a backup wrench and tighten the fuel pipe fittings to 27 N.m (20 lb ft).
10. Tighten the fuel filler cap.
11. Connect the negative battery cable.
12. Inspect for leaks.
12.1. Turn the ignition ON for 2 seconds.
12.2. Turn the ignition OFF for 10 seconds.
12.3. Turn the ignition ON.
12.4. Inspect for fuel leaks.
13. Install the distributor.
14. Install the upper intake manifold.