Fuel Rail: Service and Repair
TOOLS REQUIRED^ SA9127B 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 liquid cleaning solvent.
1. Disconnect negative battery terminal.
2. Remove air intake tube and fresh air tube.
CAUTION: 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.
3. Remove throttle cable.
4. Remove power steering support brace.
5. Relieve fuel system pressure (refer to "Relieving Fuel Pressure"). Service and Repair
6. Remove attachment nut (10 mm hex) holding fuel feed line clip to intake manifold brace.
CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around fuel lines to collect fuel, then place cloth in an approved container.
7. 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.
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:
11. Carefully pull rail back and upward to remove injectors from the intake manifold ports.
NOTE: whenever the fuel rail is removed for service, the injectors must be removed and upper and lower injector O-rings must be replaced.
12. Remove clips retaining the fuel injectors and pull injectors out of the rail.
13. 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.
14. 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:
2. With injectors pointing downward, lower the fuel line end of the fuel rail into the cavity between the cam cover and intake manifold.
3. Apply Loctite(R) 242 Threadlocker (P/N 21485277) or equivalent to the attachment bolt threads. Install fuel rail attachment bolts.
Torque: 12 N.m (105 in-lbs)
NOTE: Rotate #2 injector terminals approximately 15 degrees from vertical towards front of engine. This will provide clearance between throttle cable and #2 injector wires. Clearance is necessary to prevent abrasion of wires.
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.
4. 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.
5. Install fuel line clip to bracket with attachment bolt (10 mm hex).
Torque: 4 N.m (36 in-lbs)
6. Connect negative battery terminal.
7. 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.
8. With engine off and ignition on, pressurize the fuel system and check for leaks.
9. Install air tube and air filter cover.