Fuel Rail: Service and Repair
CAUTION:
^ DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANYTIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.
^ WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING WHILE CONNECTING GAUGE, TO COLLECT FUEL. PLACE THE CLOTH IN AN APPROVED CONTAINER.
IMPORTANT: When servicing the fuel rail assembly, be careful to prevent dirt and other contaminants from entering the fuel passages. Fittings should be capped and holes plugged during servicing. Before removal, the fuel rail may be cleaned with a spray type engine cleaner, AC Delco X-30A or equivalent, following package instructions. Do not soak rails in liquid cleaning solvent.
REMOVAL
1. Disconnect negative battery terminal.
2. Remove air intake tube and fresh air tube.
3. Perform Fuel Pressure Release procedure (refer to "Relieving Fuel Pressure".
4. Remove attachment screw (10 mm hex) holding fuel feed line clip to [1][2]intake manifold brace.
5. Disconnect the fuel supply line by compressing the two plastic retainer tabs and pulling on the fuel supply line. Remove and discard the plastic retainer.
6. Remove [1][2]PCV hose.
7. Remove throttle control cable bracket bolts, disconnect cable from throttle lever and lay over [1][2]intake manifold.
8. Disconnect injector electrical connectors.
Description:
9. Remove fuel rail assembly attachment bolts.
NOTICE: Use care in removing fuel rail assembly to prevent damage to the electrical connector terminals and spray tips. The fuel injector is serviced as a complete assembly only. Since it is electrical, it should not be immersed in any cleaner.
Description:
10. Remove fuel rail assembly:
a. Carefully pull rail back and upward to remove injectors from the [1][2]intake manifold ports.
b. Move rail towards the power steering pump.
c. Rotate rail so injectors point downward.
d. Lift the #1 injector and remove rail from between the cam cover and [1][2]intake manifold.
NOTICE: Whenever the fuel rail is removed for service, the injectors must be removed and upper and lower injector O-rings must be replaced.
11. Remove clips retaining the fuel injectors and pull injectors out of the rail.
12. Disassemble the injector O-ring seals using a special seal removal tool or brass seal pick from each injector and discard.
NOTICE: When cleaning or servicing the fuel rail, care must be taken to assure that the plastic fuel rail surfaces that mate to the injector O-rings are not scratched.
13. Lubricate the new O-ring seals with clean engine oil and install injectors into fuel rail.
INSTALLATION
IMPORTANT: Lubricate O-rings at injector tips prior to installing injectors into [1][2]intake manifold.
1. To install fuel rail assembly to [1][2]intake manifold:
a. With injectors pointing downward, lower the fuel line end of the fuel rail into the cavity between the cam cover and [1][2]intake manifold.
b. Rotate the injectors into a horizontal position.
c. Align injectors with their respective port holes.
d. Carefully push fuel injectors into holes making sure they have seated in [1][2]intake manifold.
2. Install fuel rail attaching bolts.
Torque to: 10 NM (89 in. lbs)
3. Connect fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.
4. Connect PCV valve hose and connect vacuum line to fuel pressure regulator. Make sure they are fully seated.
CAUTION: LUBRICATE WITH CLEAN ENGINE OIL THE MALE END OF THE FUEL RAIL THAT CONNECTS WITH THE FUEL SUPPLY LINE. FIRMLY PRESS ON FEMALE COUPLER UNTIL A CLICK IS HEARD, THEN PULL BACK TO CONFIRM ENGAGEMENT. PINCHED, KINKED OR DAMAGED FUEL LINES MUST BE REPLACED.
5. Lubricate with clean engine oil the male fuel feed line and male fuel return line connections. Attach the fuel feed line and pull back to confirm engagement. Attach the fuel return line and pull back to confirm engagement.
6. Install fuel line clip to bracket with attachment screw (10 mm hex).
Torque to: 4 NM (36 in. lbs)
7. Connect negative battery terminal.
8. Prime fuel system.
a. Cycle ignition on for 5 seconds and then off for 10 seconds.
b. Repeat step 8a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 8a-8c.
9. With engine off and ignition on, pressurize the fuel system and check for leaks.
10. Install air tube and air filter cover.