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Fuel Rail Assembly (SOHC): Removal

  1. Disconnect negative battery terminal.
  2. Remove air intake tube, air filter cover and fresh air tube.
  3. Remove PCV hose.
  4. Relieve pressure in fuel system at fuel pressure test port. Refer to RELIEVING FUEL PRESSURE .
    Fig 1: Relieving Fuel Pressure
    G01068227Courtesy of GENERAL MOTORS CORP.
  5. Remove fuel feed line retainer clip attachment nut (10 mm hex).
    Fig 2: Remove Fuel Feed Line Retainer Clip
    G01068228Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 3: Fuel Injector Electrical Connectors
    G01068229Courtesy of GENERAL MOTORS CORP.
  7. Remove accelerator control cable bracket bolts. Disconnect cable from throttle lever and lay over intake manifold.
  8. Disconnect injector electrical connectors.
    1. Pull pop up CPA. It is not necessary to remove CPA from connector.
    2. Squeeze connector at CPA.
    3. Pull to remove.
      Fig 4: Injector Electrical Connectors
      G01068230Courtesy of GENERAL MOTORS CORP.
  9. Remove fuel rail assembly attachment bolts.
    Fig 5: Fuel Rail Assembly Attachment Bolts
    G01068231Courtesy of GENERAL MOTORS CORP.
    NOTE: Use care in removing the 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.
    NOTE: Enough space exists between the intake manifold and cam cover to remove the fuel rail as an assembly.
  10. Remove fuel rail assembly.
    1. Carefully pull rail back and upward to remove injectors from the intake manifold ports.
    2. Move rail back against intake manifold runners.
    3. Rotate rail so injectors point upward.
    4. Move the rail against the power steering pump.
    5. Lift the #1 injector and remove the rail from between the cylinder head and intake manifold.
      Fig 6: Removing Fuel Rail Assembly
      G01068232Courtesy of GENERAL MOTORS CORP.
      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.
    Fig 7: Injector Components
    G01068233Courtesy of GENERAL MOTORS CORP.
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