Fuel Rail: Service and Repair

WARNING
To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components.
After relieving system pressure, a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is complete.
To reduce the risk of fire and personal injury that may result from a fuel leak, always replace "O" ring seals exposed during component service.

NOTE
Do Not attempt to remove the fuel inlet fitting on the fuel rail, it is staked in place. 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 the injector spray tips.
Prevent dirt and other contaminates from entering open lines and passages. Fittings should be capped, and holes should be plugged, during servicing.
Before removal, the fuel rail assembly may be cleaned with a spray type cleaner, GM X30-A or equivalent, following package instructions. Do Not immerse fuel rails in liquid cleaning solvent.

Fuel Rail/Front Fuel Pipe:

REMOVAL
1. Disconnect the negative battery terminal.
2. Relieve fuel system pressure.
3. Disconnect the hoses at the front and side of the crankcase ventilation oil/air separator.
^ Leave the vacuum hoses connected to the cannister purge solenoid.
4. Remove the bolts attaching the crankcase ventilation oil/air separator and cannister purge solenoid.
5. Disconnect the hose to the bottom of the separator, then remove the separator.
^ Position the cannister purge solenoid out of the way.
6. Remove the fuel pipe clamp bolt.
7. Disconnect the vacuum hose at the pressure regulator.
8. Remove the fuel rail attaching bolts.
9. Remove the fuel rail assembly from the cylinder head.
10. Disconnect the injector electrical connectors:
^ Push in the wire connector clip, while pulling the connector away from the injector.

Continue, if complete removal of the fuel rail is required.

11. Disconnect the fuel inlet pipe from the fuel rail.
^ Use a back-up wrench on the fuel rail inlet fitting to prevent it from turning.
12. Remove the fuel return tube retainer screw and retainer.
13. Remove the fuel outlet pipe from the pressure regulator.
14. Remove the fuel rail assembly from the engine.

CAUTION
If an injector becomes separated from the fuel rail and remains in the cylinder head, both injector O-ring seals and retainer clip must be replaced.

Fuel Rail Assembly:

DISASSEMBLY
1. Remove the injector O-ring seal from the spray tip end of each injector, and discard.
^ If an injector was separated from the rail during removal, remove both injector O-rings.
2. Remove injector retainer clips if necessary.
3. Remove the fuel inlet and return tube seal retainers and tube seals.
^ Use a small screwdriver to pry out the seal retainers.
^ Discard seals and retainers.

ASSEMBLY
1. Lubricate new injector O-ring seals with clean engine oil, and install on the injectors.
2. Install new injector retainer clips, if necessary.
3. If separated from the fuel rail, install the injectors, with the electrical connector facing outward.
^ Push in far enough to engage the retainer clip with the machined slots on the rail socket.
4. Install new fuel inlet and return tube seals and retainers.
^ Press the retainer in to contact the O-ring.

INSTALLATION
1. If the fuel rail was disconnected from the fuel pipes, reconnect the fuel pipes at this time.
^ Apply a few drops of clean engine oil to the male end of the fuel pipes before installing.
TIGHTEN
^ Return tube retainer screw to 6.0 Nm (53.0 lb.in).
^ fuel inlet pipe nut to 30 Nm (22 lb.ft).
^ Use a back up wrench on the fuel rail inlet fitting to prevent it from turning.
2. Position the fuel rail over the cylinder head, and connect the injector electrical connectors.
^ Rotate the injectors as required to avoid stretching the wire harness.
3. Position the fuel rail assembly into the cylinder head.
4. Install the fuel rail attaching bolts, and tighten to 26.0 Nm (19.0 lb.ft).
5. Connect the vacuum hose to the pressure regulator.
6. If the front fuel pipes are being replaced, install new fuel pipe O-rings at this time.
7. Connect the fuel inlet and outlet pipe connections.
^ Tighten the fuel pipe fittings to 27.0 Nm (20.0 lb.ft).
^ Use a back-up wrench to prevent the female fitting from turning.
8. Install the fuel pipe clamp bolt and tighten to 12.0 Nm (106 lb.in).
9. Connect the hose to the bottom of the crankcase ventilation oil/air separator.
10. Position the separator and canister purge solenoid over the attaching bosses.
11. Install the separator and solenoid attaching bolts and tighten to 8.0 Nm (71.0 lb.in).
12. Connect the hoses to the front and sides of the separator.
13. Tighten the fuel filler cap.
14. Connect the negative battery cable.
15. Turn the ignition switch "ON" for two seconds, then turn to the "OFF" position for ten seconds. Again turn the ignition to the "ON" position, and check for fuel leaks.