Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Service and Repair.

2. Clean the fuel rail assembly before disconnection the fuel connections.

Caution:

* Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.

* Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

3. Disconnect the fuel feed pipe from the fuel rail. Refer to Fuel Line Replacement - Engine Fuel Line Replacement - Engine.





Note:
Observe the order sequence of the fuel injector electrical connectors (1).

4. Disconnect the fuel injector electrical connectors (1) from the fuel injectors.





5. Using a suitable tool detach the engine electrical wiring harness from the fuel rail.

6. Remove the fuel rail ground strap to intake manifold retaining bolt (2).

7. Remove the fuel rail to intake manifold retaining bolts (1).

8. Simultaneously lift both sides of the fuel rail (3) and remove the fuel rail assembly from the intake manifold.





Note:
The fuel injector seals are single use items and must be replaced after the fuel injectors has been removed.

9. Remove the fuel injector seals (2) from the fuel injectors (1) and discard.

Installation Procedure





1. Lubricate the NEW fuel injector seals (2) with clean engine oil.

2. Install the NEW fuel injector seals (2) to the fuel injectors (1).





3. Install the fuel rail assembly (3) to the intake manifold.

4. Apply a 0.5 mm (0.02 in) band of GM approved threadlock to the threads of the fuel rail retaining bolts (1).

Caution:
Refer to Fastener Caution Fastener Caution.

5. Install the fuel rail to intake manifold retaining bolts (1) and tighten to 10 Nm (89 lb in).

6. Install the fuel rail ground strap to intake manifold retaining bolt (2) and tighten to 10 Nm (89 lb in).





Note:

* Do not damage the engine wiring harness.

* Observe the order sequence of the fuel injector electrical connectors (1).

7. Connect the fuel injector electrical connectors (1) to the fuel injectors.

8. Install the engine wiring electrical harness to the fuel rail.

9. Connect the fuel feed pipe to the fuel rail. Refer to Fuel Line Replacement - Engine Fuel Line Replacement - Engine.

10. Connect the negative battery cable.

11. Inspect for leaks.

1. Turn ON the ignition for 2 seconds.

2. Turn OFF the ignition for 10 seconds.

3. Turn ON the ignition.

4. Inspect for fuel leaks.