Fuel Rail: Service and Repair

WARNING: 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.

WARNING: 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.

NOTE: 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.

Fuel Injection Rail Replacement.:

Removal Of Fuel Rail Connection.:

FUEL RAIL ASSEMBLY REMOVAL

1. Disconnect negative battery terminal.

2. Remove air intake tube with resonator and fresh air tube.


3. Connect fuel gage bar kit SA9127E (or equivalent) to fuel pressure test port.

4. Install bleed hose into an approved container and open valve to bleed system pressure. Once pressure is bled, remove gauge from fuel pressure test port and recap it.

5. Remove the fuel line bracket bolt.


CAUTION: A backup wrench (24 mm or 15/16 in.) must be used to prevent damaging the pressure regulator inlet port and bracket.

6. Disconnect fuel supply and return lines at rail.

NOTE: It may be necessary to remove the fuel rail attachment bolts and rotate the fuel rail slightly for wrench access.

7. Disconnect vacuum line at pressure regulator.

8. Remove throttle control cable bracket bolts, disconnect cable from throttle lever and lay over intake manifold.

9. Disconnect injector electrical connectors.

10. Remove fuel rail assembly attachment bolts.


11. Remove fuel rail assembly:

a. Carefully pull rail back and upward to remove injectors from the intake manifold ports.

b. Rotate rail so injectors point downward.

c. Lift rail, opposite end of fuel connections to remove rail from between cam cover and intake manifold. Enough space exists between the throttle body assembly and pressure regulator for removal.
NOTE: Some DOHC (LLO) engines built prior to January 1, 1991 used the first design clip. Whenever the fuel rail is removed all four clips (P/N 21007022) must be replaced to prevent a possible injector ticking noise

CAUTION: Use care in removing fuel rail assembly to prevent damage to the injector 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.

NOTE: The throttle lever may have to be rotated slightly when removing fuel rail unit.

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12. Disassemble the injector O-ring seals using a special seal removal tool or brass seal pick from each injector and discard. If an injector is replaced or removed from the fuel rail the upper O-ring must also be replaced.

NOTE: It is not necessary to remove the O-ring retainers from the inlet and outlet ports.

13. Remove fuel inlet and return line O-rings using a special seal removal tool, or brass seal pick and discard.

WARNING: At any time the fuel system is opened for service, the O-ring seals used with related components must be replaced.

14. Lubricate the new O-ring seals with clean engine oil and install them.


INSTALLATION

1. Lubricate new fuel inlet and return line O-rings with clean engine oil and install in fuel outlet of pressure regulator and inlet of fuel rail.

NOTE: It is not necessary to remove the retainers to insert the O-rings into the fuel line nuts.

NOTE: After installation of the fuel rail assembly, attach the fuel lines prior to installing the three rail bolts.

2. To install fuel rail assembly to intake manifold:

NOTE: Throttle lever may have to be rotated slightly when installing fuel rail unit.

a. Install fuel rail assembly, injectors pointing downward, through passage between cam cover and intake manifold, from the power steering pump side of engine, pressure regulator end first. Enough space exists between the throttle body assembly and pressure regulator for installation.

b. Align injectors with their respective port holes.

c. Carefully push injectors into holes making sure they have seated on intake manifold.


3. Install fuel rail attaching bolts.
^ Torque: 30 Nm (22 ft lbs)

4. Connect injector electrical connectors. Push in until a click is heard and pull back to insure engagement.

5. Connect PCV valve hose and vacuum line to fuel pressure regulator. Make sure they are fully seated.

6. Install throttle control cable bracket bolts and attach cable if disconnected.
^ Torque: 25 Nm (19 ft lbs)

WARNING: If fuel lines were disconnected at connectors, lubricate steel line male ends with clean engine oil. Holding steel 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.

CAUTION: A backup wrench (24 mm or 15/16 in.) must be used to prevent damaging the pressure regulator inlet port and bracket.

7. Attach fuel supply and return lines to fuel rail inlet and outlet fittings.
^ Torque: Fuel Feed to Rail: 15 Nm (133 in lbs)
^ Torque: Fuel Return to Regulator: 15 Nm (133 in lbs)

8. Install fuel line clip to bracket bolt.
^ Torque: 12 Nm (106 in lbs)

9. Connect negative battery terminal.

10. Prime fuel system.

a. Cycle ignition "ON" for 5 seconds and then "OFF" for 10 seconds.

b. Repeat step 10a twice.

c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds.)

d. If engine does not start, repeat steps 10a - 10c.

11. With engine "OFF" and ignition "ON", pressurize the fuel system and check for fuel leaks.

12. Install air intake tube/resonator.