Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLYREMOVAL
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 such as AC Delco X-30A (or equivalent) following package instructions. Do not soak rails in liquid 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 Pressure").
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 accelerator control cable bracket bolts. Disconnect cable from throttle lever and lay over intake manifold.
8. Disconnect injector electrical connectors.
8.1 Pull popup CPA. It is not necessary to remove CPA from connector.
8.2 Squeeze connector at CPA.
8.3 Pull to remove.
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.
IMPORTANT: Enough space exists between the intake manifold and cam cover to remove the fuel rail as an assembly.
10. Remove fuel rail assembly.
10.1 Carefully pull rail back and upward to remove injectors from the intake manifold ports.
10.2 Move rail back against intake manifold runners.
10.3 Rotate rail so injectors point upward.
10.4 Move the rail against the power steering pump.
10.5 Lift the #1 injector and remove the rail from between the cylinder head and intake manifold.
NOTE: 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 from each injector using a special seal removal tool or brass seal pick and discard.
INSTALLATION
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.
1. Lubricate the new O-ring seats with clean engine oil and install injectors into fuel rail.
2. To install fuel rail assembly to intake manifold:
2.1 With injectors pointing upward, lower the fuel rail into the cavity between the cam cover and intake manifold.
2.2 Move rail towards power steering pump.
2.3 Rotate the injectors into a horizontal position. The fuel rail must be placed against the intake manifold runners to accomplish this.
2.4 Align injectors with their respective port holes.
2.5 Carefully push fuel injectors into holes, making sure they have seated on intake manifold.
3. Install fuel rail attaching bolts.
Torque:
Fuel Rail Attachment Bolts: 12 N.m (9 ft-lbs)
4. Connect fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.
5. Connect accelerator cable to throttle body and to accelerator cable support bracket. Attach the accelerator control cable bracket.
Torque:
Accelerator Control Cable Bracket-to-Intake Manifold (L24): 30 N.m (22 ft-lbs)
6. 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 ensure 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.
7. Lubricate with clean engine oil the male fuel feed line line connection. Attach the fuel feed line and pull back to confirm engagement.
8. Install fuel line retainer clip attachment screw (10 mm hex).
Torque:
Fuel Line Retainer Clip: 4 N.m (35 in-lbs)
9. Connect negative battery terminal.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)
10. Prime fuel system.
10.1 Cycle ignition on for 5 seconds and then off for 10 seconds.
10.2 Repeat step 9.1 twice.
10.3 Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
10.4 If engine does not start, repeat steps 9.1 - 9.3.
11. With engine off and ignition on, pressurize the fuel system and check for leaks.
12. Install intake tube and air filter cover.