Fuel Rail: Service and Repair

Fuel Rail Assembly - Exploded View:

Fuel Rail Identification:

Fuel Rail And Injectors:

FUEL RAIL ASSEMBLY

REMOVAL:

Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner, such as AC-Delco X-30A or equivalent.

CAUTION:
^ DO NOT immerse fuel rails in liquid cleaning solvents.
^ When servicing the fuel rail assembly, be careful to prevent dirt or other contaminants from entering the fuel passages. Fittings should be capped and holes should be plugged during servicing.
^ Whenever the fuel system is opened for service, the O-ring seals used with related components should be replaced.
^ Support the fuel rail to avoid damaging components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Move the power steering pump.
4. Disconnect the vacuum line from the pressure regulator and base assembly.
5. Disconnect the fuel feed line from the rear fuel rail assembly. Discard the O-ring.
6. Disconnect the fuel return line. Discard the O-ring.
7. Disconnect the electrical connectors at the front and rear rail assemblies.
8. Remove the five rail support bracket attaching bolts.
9. Remove the fuel rail assembly from the intake manifold.
10. Remove the lower injector O-rings from the injector assemblies and discard.

CAUTION: Use care in removing the fuel rail assembly to prevent damage to the injector electrical terminals or the injector spray tips. Support the fuel rail to avoid damaging the components. The fuel injector is serviced as a complete assembly only. Since it is an electrical component, the fuel injector should not be immersed in liquid cleaner.

FUEL INJECTOR REMOVAL:

1. Disconnect the electrical connector from the fuel injectors while the fuel rail assembly is inverted.
^ Push in the wire connector clip while pulling the connector body away from the injector.
2. Remove the injector retainer clip from the injector. Discard the clip.
^ Spread open the clip slightly and slide the clip away from the fuel rail.
3. Remove the fuel injector assembly.
^ Twist back and forth while removing.
4. Remove the injector O-rings and discard.

FUEL INJECTOR INSTALLATION:

1. Lubricate (using petroleum base grease only) new injector O-ring seals and install them on the injector assemblies.
2. Install new injector clips on the injector assemblies.
3. Install the fuel injector assemblies into the fuel rail sockets.
^ Push in to engage the retainer clip with the fuel rail cup.
^ The electrical connectors should be facing the engine front for injectors one through four. The electrical connectors should be facing the engine rear for injectors five through eight.
4. Connect the electrical connector to the injector assembly.

FUEL RAIL INSTALLATION:

1. Position the fuel rail into the intake manifold.
2. Install the five rail support bracket attaching bolts, tighten to 24 Nm (18 lb.ft).
3. Connect the electrical connectors to the wiring harness.
4. Connect the fuel feed line. Use a new inlet fitting O-ring. Lubricate before installation.
5. Connect the fuel return line. Use a new inlet fitting O-ring, and tighten the fittings to 30 Nm (22 lb.ft).
6. Connect the vacuum line to the pressure regulator.
7. Install the power steering pump.
8. Connect the negative battery cable.
9. Energize the fuel pump and check for fuel leaks.
10. Perform the "Idle Learn Procedure".

FUEL PRESSURE REGULATOR REMOVAL:

1. Disconnect the negative battery cable.
2. Remove the air cleaner upper housing.
3. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
4. Disconnect the fuel return line at the rear fuel rail attachment.
5. Remove the pressure regulator base screw with tool J 38458.
6. Remove the pressure regulator return line bracket screw at the rear rail.
7. Remove the pressure regulator and return pipe assembly from the fuel rail.
8. Remove the pressure regulator return pipe from the pressure regulator.

CAUTION: Use care in removing the pipe so as not to damage the O-ring sealing surface.

9. Remove the regulator O-ring and discard.

FUEL PRESSURE REGULATOR INSTALLATION:

1. Lubricate the new O-ring (using petroleum base grease only). Install the new O-ring on the regulator.
2. Install the regulator return pipe in the pressure regulator assembly.
3. Connect the pressure regulator and pipe assembly to the fuel rail.
4. Install the pressure regulator attaching screw.
5. Install the regulator return pipe attaching screw at the rear rail, and tighten the regulator attaching screw to 5 Nm (44 lb.in), tighten return pipe attaching screw.
6. Connect the fuel return line to the rear rail.
7. Install the air cleaner upper housing.
8. Connect the negative battery cable.
9. Energize the fuel pump and check for fuel leaks.
10. Perform the "Idle Learn Procedure", refer to MAINTENANCE PROCEDURES/IDLE LEARN PROCEDURE.