Fuel Rail Replacement: Removal

CAUTION: PLACE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEAR WORK AREA BEFORE ATTEMPTING AN ON-VEHICLE SERVICE.

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

NOTE: Cap fuel fittings and plug port holes when servicing fuel system in order to prevent dirt and other contaminants from entering open areas.

Disconnect negative battery terminal.
Relieve fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELIEF .

Fig 1: Relieving Fuel System Pressure
Courtesy of GENERAL MOTORS CORP.
Disconnect fuel lines.
Remove intake plenum.
Disconnect fuel injector electrical harness connector.
Disconnect fuel injector connectors.
Remove fuel rail attaching bolts from intake manifold.
Disconnect fuel pressure regulator vacuum line.
CAUTION: WEAR SAFETY GLASSES WHEN USING COMPRESSED AIR IN ORDER TO PREVENT EYE INJURY.
Use compressed air to blow debris away from area where injectors enter intake manifold.
Remove fuel injector locking clips. Pry each fuel injector from intake manifold.
Remove fuel rail assembly.

Fig 2: Removing Fuel Rail Assembly
Courtesy of GENERAL MOTORS CORP.
Remove fuel injector assemblies from fuel rail.
IMPORTANT: Any time fuel system is opened for service, O-ring seals used with related components must be replaced.
Remove rust or burrs from engine fuel pipes using the following procedures.
1. Use emery cloth in order to remove rust or burrs from fuel pipes. Use a radial motion on fuel pipe end in order to prevent damage to O-ring sealing surface.
2. Use a clean shop towel to wipe male tube ends clean.
3. Inspect all connectors for dirt and burrs. Clean or replace damaged components as necessary.
Remove O-rings from fuel injectors.