REMOVAL: Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner, such as AC-Delco X-30A or equivalent.
CAUTION: DO NOT immerse fuel rails in liquid cleaning solvents.
When servicing the fuel rail assembly, be careful to prevent dirt or other contaminants from entering the fuel passages. Fittings should be capped and holes should be plugged during servicing.
Whenever the fuel system is opened for service, the O-ring seals used with related components should be replaced.
Support the fuel rail to avoid damaging components.
Disconnect the negative battery cable.
Remove the air cleaner.
Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
Move the power steering pump.
Disconnect the vacuum line from the pressure regulator and base assembly.
Disconnect the accelerator cable, cruise control cable and bracket.
Disconnect the electrical connectors from the TPS, ISC, CTS and MAT sensors.
Remove the coolant hose to thermostat housing.
Disconnect the fuel feed line from the rear fuel rail assembly. Discard the O-ring.
Disconnect the fuel return line. Discard the O-ring.
Disconnect the EGR vacuum lines from the EGR valve.
Remove the five rail support bracket bolts.
Disconnect the electrical connectors at the front and rear fuel rail assemblies.
Remove the fuel rail assembly from the intake manifold.
REMOVAL: Disconnect the injector electrical connector while the fuel rail is inverted.
Push in the wire connector clip while pulling the connector body away from the injector.
Remove the retainer clip from the injector. Discard the clip.
Spread open the clip slightly and slide the clip away from the fuel rail.
Remove the fuel injector assembly.
Twist back and forth while removing.
Remove the O-ring seals from the injector and discard.
ASSEMBLY: Lubricate new injector O-ring seals with clean engine oil and install on the injector assemblies.
Install new injector clips on the injector assemblies.
Install the fuel injector assemblies into the fuel rail sockets.
Push in to engage the retainer clip with the fuel rail cup.
The electrical connectors should be facing the engine front for injectors one through four. The electrical connectors should be facing the rear for injectors five through eight.
Connect the electrical connector to the injectors.
Proceed to FUEL RAIL INSTALLATION.
FUEL PRESSURE REGULATOR
REMOVAL: After the fuel rail is removed, remove the fuel return line at the rail attachment.
Remove the pressure regulator base screw with tool J 38458 or equivalent.
Remove the pressure regulator return line bracket screw from the rear rail.
Remove the pressure regulator return pipe from the pressure regulator.
Use care in removing the pipe so as not to damage the O-ring seating surface.
Remove the regulator O-ring and discard.
INSTALLATION: Lubricate a new O-ring with clean engine oil and install it on the regulator.
Install the regulator return pipe in the pressure regulator assembly and tighten the nut to 18 Nm (13 lb. Ft).
Install the pressure regulator assembly on the fuel rail.
Install the pressure regulator attaching screw, and tighten to 12 Nm (9 lb. Ft).
Install the regulator return pipe attaching screw to the rear rail, and tighten to 12 Nm (9 lb. Ft).
Connect the fuel return line at the rear rail.
FUEL RAIL INSTALLATION: NOTE: Lubricate new injector O-ring seals with clean engine oil, and install on the fuel injector tips.
Install the fuel rail assembly to the intake manifold.
Install the five rail support bracket bolts, and tighten to 24 Nm (18 lb. Ft).
Connect the electrical connector at the front and rear fuel rail assemblies.
Install the EGR valve and vacuum lines.
Connect the fuel feed line. Use a new O-ring. Lubricate the O-ring with a petroleum based grease before installation.
Connect the fuel return line. Use a new O-ring. Lubricate the O-ring with a petroleum based grease before installation, and ising a back-up wrench to prevent damage, tighten both the fuel feed and return lines to 30 Nm (22 lb. Ft).
Connect the coolant hose to the thermostat housing.
Connect the electrical connectors to the TPS, ISC, coolant and MAT sensors.
Connect the accelerator cable, cruise control cable, and bracket.
Connect the vacuum line to pressure regulator and base assembly.
Install the power steering pump.
Install the air cleaner.
Connect the negative battery cable.
Energize the fuel pump and check for fuel leaks.
Perform the IDLE LEARN PROCEDURE, refer to MAINTENANCE PROCEDURES/IDLE LEARN PROCEDURES.