Fuel Rail Removal and Replacement Procedure
Fuel Rail Removal and Replacement Procedure
Tools Required
^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Fuel Line Disconnect Tool Set
^ J 41081 Injector Remover
Notice
Do NOT remove the air cleaner assembly, intake air duct, throttle body or EGR pipe. The replacement fuel rail does not require the removal of these components due to the revised design. Removal of components not necessary for this procedure will require replacement of damaged gaskets and EGR pipe.
Fuel Rail Removal
1. Allow the engine too cool to ambient temperature.
2. Note the customer's radio settings.
3. Raise the hood.
4. Open the fuel filler door.
5. Unscrew the fuel filler cap in order to relieve gas tank pressure.
Caution
Before servicing any electrical component, the ignition key must be in the Off or LOCK position and all electrical loads must be Off, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
6. Disconnect the negative cable at the battery.
7. Remove the 4 fuel injector sight shield nuts.
8. Remove the fuel injector sight shield.
Caution
^ Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.
^ After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
9. Relieve the fuel rail pressure at test port connection with the J 34730-1A.
A. Wrap a shop towel around test port connection while connecting gage to avoid spillage.
B. Connect the gage to the test port connection.
C. Install the bleed hose into an approved container.
D. Open bleed valve to bleed system pressure.
E. Drain any fuel remaining in the J 34730-1A into an approved container.
10. Tighten the fuel filler cap.
11. Close the fuel filler door.
Important
Steps 12-18 MY 1995-96 Cadillac ONLY.
12. Disconnect the vacuum manifold from the intake manifold adapter and reposition.
13. Disconnect the transmission vent tube from the retainer on the cruise control servo bracket.
14. Release the retainer holding the vacuum hoses onto the cruise control servo bracket.
15. Remove the cruise control servo bracket bolts.
16. Disconnect the vacuum hoses from the cruise control servo.
17. Disconnect the cruise control servo cable from the throttle body cruise control servo cam.
18. Reposition the cruise control servo.
Caution
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
19. Blow dirt our from around fuel injectors, fuel pressure regulator, and the fuel injector wiring harness connectors using compressed air.
Important
Step 20 MY 1995-97 Cadillac ONLY
20. Remove the retainer (4, 5) from the quick-connect fittings of each fuel line.
21. Grasp both sides on either side of the quick-connect fitting and twist the female (rail side) connector 1/4 turn in each direction to loosen any dirt within the fitting.
22. Repeat Step 21 to second fuel line.
23. Blow dirt out of the fittings using compressed air.
Important
Steps 24-29 MY 1995-97 Cadillac ONLY.
24. Remove the fuel rail bracket nut from the EGR stud.
25. Place a shop towel below the fuel line fittings while disconnecting to avoid spillage.
26. Using the proper sized tool for the upper fuel line (J 37088-1, 3/8 in) from the J 37088-A tool set, insert the tool into the female connector and push in, in order to release the locking tabs.
27. Pull the upper fuel line connection apart.
28. Using the proper sized tool for the lower fuel line (J 37088-2, 5/16 in) from the J 37088-A tool set, insert the tool into the female connector and push in, in order to release the locking tabs.
29. Pull the lower fuel line connection apart.
Important
Steps 30-34 MY 1995-97 Aurora ONLY)
30. Place a shop towel below the fuel line fittings while disconnecting to avoid spillage.
31. Squeeze the plastic retainer tabs in order to release the locking tabs.
32. Pull the upper fuel line connection apart.
33. Repeat Steps 31 and 32 for the lower fuel line.
34. Remove the [1][2]PCV rear hose.
Important
Step 35 MY 1997 Cadillac ONLY)
35. Disconnect and remove the [1][2]PCV front hose.
36. Remove the spark plug harness retainer from the fuel injector sight shield stud.
37. Disconnect the front spark plug wires from the front spark plugs and reposition.
Important
Steps 38-41 MY 1997 Cadillac ONLY.
38. Disconnect and remove the [1][2]PCV front hose.
39. Disconnect and remove the brake booster hose.
40. Disconnect and remove the EVAP tube between the intake manifold adapter and the EVAP solenoid.
41. Disconnect and remove the fuel pressure regulator hose.
Important
Steps 42-47 MY 1995-97 Cadillac ONLY)
42. Disconnect the remove the [1][2]PCV rear hose.
43. Disconnect the brake booster hose from the intake manifold adapter and reposition.
44. Disconnect and remove the fuel pressure regulator hose.
45. Remove any retainers and pull the throttle body heater pipe off of the fuel injector sight shield studs and reposition.
46. Remove the fuel injector sight shield studs and spacers.
47. Disconnect the fuel injector wiring harness from the 8 fuel injectors and reposition the fuel injector wiring harness.
Important
Steps 48-51 MY 1995-97 Aurora ONLY.
48. Disconnect the fuel regulator hose from the fuel regulator.
49. Remove the fuel rail bracket bolt from the engine lift bracket.
50. Remove the fuel injector sight shield studs and spacers.
51. Disconnect the fuel injector wiring harness from the 8 fuel injectors and reposition the fuel injector wiring harness.
52. Remove the grounding harness bolt from the front of the right (rear) cylinder head.
53. Remove the fuel rail ground harness.
Notice
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
54. Reinstall the grounding harness bolt with the ECM/ignition coil ground harness.
Tighten
Tighten the grounding harness to 25 Nm (18 lb ft).
55. Cut the fuel rail flexible plastic tubes with diagonal cutters.
56. Release the locking tabs holding the fuel rail to the intake manifold.
Notice
^ 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.
57. Remove the fuel rail and fuel injectors as an assembly from the intake manifold. Use the J 41801 to aid in removing any injectors stuck in the intake manifold. Place the J 41081 between the intake manifold and the bottom of the fuel injector.
Important
Step 58 MY 1995-97 Cadillac ONLY.
58. In order to pull the metal fuel line out from under the intake manifold adapter, using pliers collapse the left (front) metal line tube at the right (rear) side of the intake manifold adapter. Weakening the tube will allow the left (front) metal line tube to be pulled out from under the intake manifold adapter on the right (rear) side of the intake manifold adapter.
59. Place the old fuel rail assembly on a clean, flat surface next to and in the same orientation as the new fuel rail assembly.