Fuel Rail Replacement

Fuel Rail:

BEFORE REMOVAL
The fuel rail assembly may be cleaned with a spray type engine cleaner, GM X-30A or equivalent, following package instructions. Do Not soak fuel rails in liquid cleaning solvent.

REMOVE OR DISCONNECT
1. Negative battery cable.

2. Relieve fuel system pressure. Refer to the Fuel Pressure Relief Procedure.

3. Resonator.

4. Quick-connect fittings at engine fuel pipes:

A. Slide rubber dust covers from quick-connect fittings at engine fuel pipes.
B. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within fitting.

CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

C. Using compressed air, blow dirt out of fitting.
D. Choose correct tool from J 37088-A tool set for size of fitting. Insert tool into female connector, then push-pull inward to release locking tabs.
E. Pull connection apart.

CLEAN AND INSPECT

NOTE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to 0-ring sealing surface.

^ Using a clean shop towel, wipe off male pipe end.
^ Inspect both ends of fitting for dirt and burrs. Clean or replace components and assemblies as required.

5. Vacuum lines at pressure regulator and Evaporative Emissions (EVAP) canister purge solenoid.

6. Electrical harness and cables from routing clips on resonator bracket.

7. Resonator bracket.

8. Injector electrical connectors.

^ Identify connectors to their corresponding injectors to assure correct sequential injector firing order after reassembly.

9. Fuel rail assembly.

DISASSEMBLE
Injector lower 0-ring seal (brown) from spray tip end of each injector. Discard 0-ring seals. Save 0-ring backups.

IMPORTANT: The fuel injector lower 0-ring uses a nylon collar, called the 0-ring backup, to properly position the 0-ring on the injector. Be sure to reinstall the 0-ring backup, or the sealing 0-ring may move on the injector when installing the fuel rail and result in a possible vacuum leak and driveability complaints will occur.

ASSEMBLE
Lubricate new lower injector 0-ring seals (brown) and install on spray tip end of each injector.

INSTALL OR CONNECT
1. Fuel rail assembly to intake manifold.

2. Resonator bracket.

Tighten
Fuel rail and resonator bracket attaching bolts to 10 Nm (89 lb in).

3. Injector electrical connectors.

^ Make sure that each connector is installed on the proper injector to assure correct sequential injector firing order.
^ Rotate injector(s) as required to avoid stretching wire harness.

4. Electrical harness and cables into routing clips on resonator bracket.

5. Vacuum lines to EVAP canister purge solenoid and fuel pressure regulator.

6. Quick-connect fittings to engine fuel pipes:

A. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet tubes.
B. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
C. Once installed, pull on both sides of fitting to make sure connection is secure.
D. Slide dust covers over quick-connect fittings.

7. Tighten fuel filler cap.

8. Negative battery cable.

INSPECT
Turn ignition switch to "ON" position for two seconds, then turn "OFF" for ten seconds. Again turn to "ON" position and check for fuel leaks.

9. Resonator.