Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.




2. Refer to Quick Connect Fitting(s) Service (Metal Collar) in order to disconnect the following from the fuel rail:
- The fuel return hose/pipe (1)
- The fuel feed hose/pipe (2)




3. Disconnect the atmospheric vent hose (2) from the following:
- The air cleaner resonator (1)
- The fuel pressure regulator (3)




4. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to disconnect the evaporative emission (EVAP) purge hose (1) from the following:
- The throttle control module (2)
- The EVAP canister purge solenoid valve (3)
5. Remove the intake manifold.




6. Disconnect the fuel injector harness connector (2) from the engine wiring harness electrical connector.
7. Before removal, clean the fuel rail assembly and the cylinder head 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.




8. Remove the fuel rail bolts.
9. Remove the fuel rail from the cylinder head.

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.




10. Remove the fuel injector lower O-ring seal (4) from the spray tip end of each fuel injector (3).Discard the O-ring seal (4).
11. If the fuel rail is not being replaced, go to the Installation Procedure.

DISASSEMBLY PROCEDURE
1. Remove the fuel injectors.
2. Remove the fuel pressure regulator.
3. Remove the fuel injector harness from the fuel rail.

ASSEMBLY PROCEDURE
1. Install the fuel injector harness to the fuel rail.
2. Install the fuel pressure regulator.
3. Install the fuel injectors.

INSTALLATION PROCEDURE




1. Lightly lubricate the new lower fuel injector O-ring seals (4) with mineral oil GM P/N 9981704.
2. Install the new O-ring seals (4) on the spray tip end of each fuel injector (3).




3. Position the fuel rail to the cylinder head, inserting the spray tip ends of the fuel injectors.
4. Install the fuel rail bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

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




5. Connect the fuel injector harness connector (2) to the engine wiring harness electrical connector.
6. Install the intake manifold.




7. Refer to Quick Connect Fitting(s) Service (Plastic Collar) in order to connect the EVAP purge hose (1) to the following:
- The throttle control module (2)
- The EVAP canister purge solenoid valve (3)




8. Connect the atmospheric vent hose (2) to the following:
- The air cleaner resonator (1)
- The fuel pressure regulator (3)




9. Refer to Quick Connect Fitting(s) Service (Metal Collar) in order to connect the following to the fuel rail:
- The fuel return hose/pipe (1)
- The fuel feed hose/pipe (2)
10. Inspect for leaks.
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.