Fuel Rail Disassembly and Assembly

Notice
^ Do not use compressed air to test or clean a fuel pressure regulator. Excessive air pressure can damage the fuel pressure regulator.

^ Do not immerse the fuel pressure regulator in a cleaning solvent in order to prevent damage to the regulator.

^ Use ONLY clean engine oil to lubricate 0-rings. In order to prevent damage to the fuel pressure regulator, do NOT use any other type of lubricant.

1. Remove the fuel regulator from the old fuel rail assembly.

A. Remove the fuel pressure regulator retaining clip (3).

B. Lift, twist and remove the fuel rail regulator (6) from the fuel rail socket.

2. Install the NEW fuel pressure regulator seals, back-up spacer and filter from the seal kit (P/N 17800050, 51, 52 or 53) onto the existing fuel pressure regulator in proper order.

A. Install the NEW 0-ring back-up (1) onto the fuel pressure regulator.

B. Coat the NEW large 0-ring (2) with clean engine oil and install onto the fuel regulator.

C. Install thew NEW regulator filter screen (3) onto the fuel regulator.

D. Coat the NEW small 0-ring (4) with clean engine oil and install onto the fuel regulator.

3. Install the fuel pressure regulator assembly into the NEW fuel rail (P/N 12583145, 46 or 47).

A. Insert the assembled fuel pressure regulator (1) into the fuel rail socket using a turning motion to properly seat the 0-rings.

B. Install the NEW fuel pressure regulator retaining clip (2).

4. Exchange each fuel injector from the old fuel rail assembly to the NEW fuel rail assembly one at a time in order to keep each injector in its original position.

A. Spread and release the fuel injector clip from the old fuel rail assembly.

B. Remove the fuel injector assembly (1).

C. Remove the upper (3) and lower (2) fuel injector 0-rings.

Important
Use ONLY clean engine oil to lubricate 0-rings. Do NOT use any other type of lubricant or grease.

D. Coat with clean engine oil the NEW 0-rings and install onto the fuel injector assembly.

E. Install the fuel injector assembly into the same location on the NEW fuel rail assembly with the wiring harness connector facing outboard direction.

F. Install the NEW fuel injector clip onto the NEW fuel rail assembly.

G. Repeat Steps 4.A through 4.G on the remaining fuel injectors.

Important
Step 5 MY 1995-97 Aurora ONLY

5. Transfer the plastic fuel line retainers from the old fuel rail to the NEW fuel rail.