Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the intake manifold.
3. Before removal, clean the fuel rail assembly and the cylinder head with a spray type engine cleaner, GM X-30 A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
4. Disconnect the fuel pressure regulator vacuum line.




5. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
6. Disconnect the fuel injector harness in-line connector.




7. Remove the fuel rail attaching bolts.

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.

8. Remove the fuel rail assembly.




9. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3).
10. Discard the O-ring seals.
11. If the fuel rail is not being replaced, go to the Installation Procedure.

DISASSEMBLY PROCEDURE
1. Remove the fuel injectors.
2. Remove the fuel pressure regulator.
3. Remove the fuel injector harness from the fuel rail.

ASSEMBLY PROCEDURE
1. Install the fuel injector harness to the fuel rail.
2. Install the fuel pressure regulator.
3. Install the fuel injectors.

INSTALLATION PROCEDURE




1. Lubricate the new lower injector O-ring seals (4) with clean engine oil.
2. Install the new O-ring seals (4) on the spray tip end of each injector (3).




3. Install the fuel rail assembly.

NOTE: Refer to the Fastener Notice in Service Precautions.

4. Install the fuel rail attaching bolts.

Tighten
Tighten the bolts to 10 N.m (89 lb in).




5. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
6. Connect the fuel injector electrical connectors.




7. Connect the fuel pressure regulator vacuum line.
8. Install the intake manifold.
9. Connect the negative battery cable.
10. Inspect for leaks.
10.1. Turn ON the ignition, with the engine OFF for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition, with the engine OFF.
10.4. Inspect for fuel leaks.