Fuel Rail: Service and Repair

Removing Plenum And Fuel Rail:

Fuel Rail Assembly:

Removing the fuel rail assembly from the engine requires removing the top portion of the tuned intake manifold called the intake air plenum.

NOTICE: 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.


CLEAN
Before removal, the fuel rail assembly may he cleaned with a spray type engine cleaner, GM X-3OA 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 System / Service and Repair. Service and Repair
3. Intake air plenum.
4. Engine fuel pipes at rail.
5. Fuel Pressure Regulator from fuel rail.
6. Fuel inlet pipe and fuel pressure regulator inlet 0-rings and discard.
7. Main injector electrical connector.
8. Coolant temperature sensor electrical connector.
9. Fuel rail retaining bolts.
10. Fuel rail assembly.

DISASSEMBLE
Injector O-ring seal from spray tip end of each injector. Discard seals. With the 0-ring removed, the 0-ring backup may slip off of the injector. Be sure to retain 0-ring backup for reuse.

ASSEMBLE
Ensure that 0-ring backups are on injectors before installing new 0-rings. Lubricate new injector 0-ring seals with clean engine oil and install on spray tip end of each injector.

INSTALL OR CONNECT
1. Fuel rail assembly in intake manifold. Tilt rail assembly to install injectors.
2. Fuel rail attaching bolts.

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

3. Coolant temperature sensor electrical connector.
4. Main injector electrical connector.
5. New 0-rings on fuel inlet line and fuel pressure regulator.
6. Fuel feed pipe.

Tighten
Engine fuel pipe nut to 17 Nm (13 lb. ft.).

7. Fuel pressure regulator.
8. Upper intake manifold.
9. Negative battery cable.
10. Fuel filler cap.

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