Fuel Rail: Service and Repair

Intake Plenum And Runners:

Fuel Rail Removal And Installation:

WARNING: To reduce the risk of fire and personal injury that may result from a fuel leak, always replace any O-ring seal exposed during component service.

CAUTION: Use care in removing the fuel rail assembly, to prevent damage to the injector spray tips and injector electrical connector pins. When removed, support the rail to avoid damaging its components.
^ Prevent dirt and other contaminates from entering open lines and passages. Fittings should be capped, and holes plugged, during service.
^ Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner, GM X-30A or equivalent. DO NOT soak fuel rails in liquid cleaning solvent.

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, see MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Remove the intake plenum and runners, see INTAKE PLENUM AND RUNNERS.
4. Remove the fuel feed and return lines, using a back-up wrench to support the fuel rail tube fittings.
5. Remove the fuel line O-rings, and discard.
6. Remove the fuel tube bracket bolt.
7. Remove the vacuum line from the pressure regulator.
8. Disconnect the fuel injector electrical connectors.
9. Remove the fuel rail attaching bolts.
10. Remove the fuel rail assembly.
11. Remove the O-ring seal from the tip of each injector, and discard.

INSTALLATION:

1. Lubricate new injector O-ring seals with clean engine oil, and install on the tip of each injector.
2. Install the fuel rail assembly into the intake manifold.
3. Install the fuel rail attaching bolts, and the fuel tube bracket bolt, and tighten to:
^ Fuel rail attaching bolts to 20.0 Nm (15.0 lb.ft).
^ Fuel tube bracket bolt to 34 Nm (25.0 lb.ft).
4. Connect the injector electrical connectors.
^ Rotate the injectors as required to avoid stretching the wire harness.
5. Connect the vacuum line to the pressure regulator.
6. Lubricate new O-rings and install them on the fuel feed and return lines.
7. Connect the fuel lines, and tighten to 27.0 Nm (20.0 lb.ft), using a back-up wrench to support the fuel rail tube fittings.
8. Check for fuel leaks:
a. Temporarily connect the negative battery cable.
b. With the engine OFF and the ignition ON, check for fuel leaks.
c. Disconnect the negative battery cable.
9. Install the intake plenum and runners.
10. Connect the negative battery cable.