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Fuel Rail Replacement: Removal

WARNING: 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.
CAUTION: 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.
    Fig 1: Removing Air Intake Tube & Fresh Air Tube
    G01019336Courtesy of GENERAL MOTORS CORP.
    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. Relieve fuel system pressure. See Figure . Refer to FUEL SYSTEM PRESSURE RELIEF  .
  4. Disconnect fuel pressure regulator hose from throttle body and fuel rail.
    Fig 2: Disconnecting Fuel Pressure Regulator Hose
    G01019338Courtesy of GENERAL MOTORS CORP.
    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.
  5. 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.
  6. Remove throttle body.
    Fig 3: Removing Throttle Body
    G01019339Courtesy of GENERAL MOTORS CORP.
  7. Remove throttle control cable bracket bolts, disconnect cable from throttle lever and lay over intake manifold.
  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: See Figure .
    1. Carefully pull rail back and upward to remove injectors from the cylinder head ports.
    2. Move rail towards the power steering pump.
    3. Rotate rail so injectors point downward.
    4. Lift the #1 injector and remove rail.
    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.
    Fig 4: Removing Fuel Injectors
    G01019341Courtesy of GENERAL MOTORS CORP.
  12. 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 ensure that the plastic fuel rail surfaces that mate to the injector O-rings are not scratched.
  13. Lubricate the new O-ring seals with clean engine oil and install injectors into fuel rail.
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