Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
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.
1. Clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
2. Disconnect the fuel feed and return pipes (2, 3) from the fuel rail.
3. Disconnect the fuel pressure regulator vacuum hose.
4. Disconnect the positive crankcase ventilation (PCV) air tube from the cam cover.
5. Disconnect the PCV valve (1) from the cam cover.
6. Remove the fuel rail bracket retainer nut.
7. Disconnect the fuel injector electrical connectors (1) from each fuel injector (2).
8. Lay the harness aside.
9. Remove the engine wiring harness from the fuel rail studs.
10. Remove the fuel rail attaching studs (2).
11. Remove the fuel rail (1).
12. Remove the injector lower O-ring seal from the spray tip end of each injector.
13. Discard the O-ring seals.
14. If replacing the fuel rail, remove the fuel injectors.
DISASSEMBLY PROCEDURE
1. Remove the fuel injectors (5).
2. Remove the fuel pressure regulator (10).
ASSEMBLY PROCEDURE
1. Install the fuel pressure regulator (10).
2. Install the fuel injectors (5).
INSTALLATION PROCEDURE
1. Lubricate the new lower injector O-ring seals with clean engine oil.
NOTE:
- Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
- Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
- Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.
1. If replacing the fuel rail, install the fuel injectors.
2. Install the new O-ring seals on the spray tip end of each injector.
3. Install the fuel rail (1).
4. Install the fuel rail attaching studs (2).
NOTE: Refer to Fastener Notice in Service Precautions. Vehicle Damage Warnings
Tighten
Tighten the studs to 10 N.m (89 lb in).
5. Connect the fuel injector electrical connectors (1) to each fuel injector (2).
6. Install the fuel rail bracket retainer nut.
Tighten
Tighten the nut to 10 N.m (89 lb in).
7. Install the positive crankcase ventilation (PCV) valve (1) to the cam cover.
8. Install the coolant surge tank inlet pipe.
9. Install the PCV air tube to the cam cover.
10. Connect the fuel pressure regulator vacuum hose.
11. Connect the fuel feed and return pipes (2, 3) to the fuel rail.
12. Connect the negative battery cable.
13. Inspect for fuel leaks using the following procedures:
13.1. Turn ON the ignition, with the engine OFF for 2 seconds.
13.2. Turn OFF the ignition for 10 seconds.
13.3. Turn ON the ignition, with the engine OFF.
13.4. Inspect for fuel leaks.
14. Install the fuel injector sight shield.