Fuel Rail: Service and Repair

Fuel Rail And Injectors:

Fuel Injector Location Typical:

FUEL RAIL


NOTE: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminates from entering the fuel passages. It is recommended that fittings be capped, and holes be plugged, during servicing. At any time the fuel system is opened for service, the "O" ring seals used with related components should be replaced.

REMOVAL:

1. Before servicing any component the fuel pressure must be relieved. See MAINTENANCE PROCEDURES/FUEL PRESSURE RELIEF.
2. Verify the ignition switch is in the "OFF" position.
3. Remove the injector electrical connections.
4. Remove the fuel supply and return lines, and the pressure regulator vacuum hose.

5. Remove the fuel rail mounting bolts.
6. Remove the fuel injector retainer clips and remove the fuel rail assembly.

NOTE: Before disassembly, the fuel rail may be cleaned with a spray type cleaner, such as AC Delco X30-A, or equivalent, following package instructions. The fuel rail should not be immersed in liquid solvent.

INSTALLATION:

1. After replacing the "O" rings on the injectors carefully position the fuel rail on the injectors, insert injector retaining clips, and insert the fuel rail mounting bolts and tighten to 20-27 Nm (14-19 lb.ft).
2. Connect the fuel supply and return lines, and the pressure regulator vacuum line.
3. Install injector electrical connections.

FUEL INJECTORS

REMOVAL:

NOTE: Use care in removing the fuel injectors to prevent damage to the electrical connector pins on the injector and to prevent damage to the injector nozzle. The fuel injector is serviced as a complete assembly only. The fuel injector is an electrical component and should not be immersed in any type of cleaner.

1. Remove the fuel rail assembly. See FUEL RAIL REMOVAL above.
2. While lifting up on the injector, use a gentle rocking motion to remove the injector.

INSTALLATION:

1. If the original injectors are being replaced, new "O" rings must be used. If new injectors are being installed, "O" rings are supplied with the injector.
2. Gently insert the injector into the intake manifold using a gentle rocking motion.
3. Install the fuel rail assembly. See FUEL RAIL INSTALLATION.

FUEL PRESSURE REGULATOR

REMOVAL:

1. Relieve the fuel pressure. See MAINTENANCE PROCEDURES/FUEL PRESSURE RELIEF.
2. Remove the fuel pressure regulator from the fuel rail. Place a shop towel around the base of the regulator to catch any spilled fuel.
3. Disconnect the fuel and vacuum lines.

INSTALLATION:

1. Connect the fuel and vacuum lines.
2. Install regulator on the fuel rail and tighten mounting bolts.
3. START engine and check for leaks.