Fuel Rail: Service and Repair

An eight digit identification number is located on the fuel rail assembly. Refer to this number if servicing or part replacement is required. 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.

NOTE:
^ Remove the attaching bolts securing the fuel rail assembly to the lower intake manifold in order to prevent damage to the fuel rail assembly.
^ Carefully remove the fuel rail assembly in order to prevent damage to the injector electrical connector terminals and the injector spray tips.
^ Cap the fittings and plug the holes plugged when servicing the fuel rail in order to prevent dirt and other contaminants from entering open lines and passages. Clean the fuel rail assembly with a GM X-30A spray type engine cleaner or the equivalent before removal. Do Not submerge the fuel rail in a cleaning solvent

REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Remove the intake manifold plenum.
4. Remove the high voltage switch assembly.
5. Disconnect the engine fuel pipes at the rail.
6. Remove the engine fuel pipe bracket bolt.
7. Remove the fuel inlet and return line O-rings and discard.
8. Disconnect the injector electrical connectors and remove from the coil bracket.
9. Remove the fuel rail retaining bolts (5).
10. Disconnect the vacuum hose line to pressure regulator.




11. Remove the fuel rail from the intake manifold.
12. Remove the injector O-ring seal from the spray tip end of each injector. Discard the seals. With the O-ring removed, the O-ring backup may slip off of the injector. Be sure to retain O-ring backup for reuse.

INSTALLATION PROCEDURE





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

1. Install the fuel rail assembly in intake manifold. Tilt the rail assembly to install the injectors.





NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attaching bolts to 10 N.m (89 lb in).

3. Connect the injector electrical connectors.
4. Install the new O-rings on the fuel pipes.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Connect the fuel feed and return lines.

Tighten
^ Engine fuel pipe nuts to 27 N.m (20 lb ft).
^ Use a back-up wrench on the fittings to prevent them from turning.

6. Connect the negative battery cable.
7. Install the fuel filler cap.
8. Check for fuel leaks.
8.1. Turn the ignition switch to the ON position for 2 seconds.
8.2. Turn the ignition switch to the OFF position for 10 seconds.
8.3. Again, turn the ignition switch to the ON position.
8.4. Check for fuel leaks.
9. Install the intake manifold plenum.