Fuel Rail: Service and Repair
TOOLS REQUIRED^ SA9127E Gauge Bar Set
Removal
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.
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 cleaning solvent.
1. Disconnect negative battery terminal.
2. Remove air intake tube, air filter cover and fresh air tube.
3. Remove PCV hose.
CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around fitting while connecting gauge, to collect fuel. place cloth in an approved container.
4. Relieve pressure in fuel system at fuel pressure test port (refer to "Relieving Fuel System Pressure"). Service and Repair
5. Remove fuel feed line retainer clip attachment nut (10 mm hex).
CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around fitting while connecting gauge, to collect fuel. place cloth in an approved container.
6. 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.
7. Remove throttle control cable bracket bolts. Disconnect cable from throttle lever and lay over intake manifold.
8. Disconnect injector electrical connectors.
9. Remove fuel rail assembly attachment bolts.
NOTE: 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.
10. Remove fuel rail assembly.
IMPORTANT: Enough space exists between the intake manifold and cam cover to remove the fuel rail as an assembly.
a. Carefully pull rail back and upward to remove injectors from the intake manifold ports.
b. Move rail back against intake manifold runners.
c. Rotate rail so injectors point upward.
d. Move the rail against the power steering pump.
e. Lift the #1 injector and remove the rail from between the cylinder head and intake manifold.
IMPORTANT: 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.
NOTE: 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 intake manifold.
1. To install fuel rail assembly to intake manifold:
a. With injectors pointing upward, lower the fuel rail into the cavity between the cam cover and intake manifold.
b. Move rail towards power steering pump.
c. Rotate the injectors into a horizontal position. The fuel rail must be placed against the intake manifold runners to accomplish this.
d. Align injectors with their respective port holes.
e. Carefully push fuel injectors into holes, making sure they have seated on intake manifold.
2. Install fuel rail attaching bolts.
Torque: 10 N.m (89 in-lbs)
3. Connect fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.
4. Connect throttle cable to throttle body, and throttle cable support bracket. Attach the accelerator control cable bracket.
Torque: 30 N.m (22 in-lbs)
5. Connect PCV valve hose.
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.
NOTE: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to assure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.
6. Lubricate with clean engine oil the male fuel feed line line connection. Attach the fuel feed line and pull back to confirm engagement.
7. Install fuel line retainer clip attachment screw (10 mm hex).
Torque: 4 N.m (36 in-lbs)
8. Connect negative battery terminal.
9. 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.
10. With engine off and ignition on, pressurize the fuel system and check for leaks.
11. Install intake tube and air filter cover.