GM Full-Size Trucks 1988-1998 Repair Information

Fuel Rail Assembly

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REMOVAL & INSTALLATION



See Figure 1

Clean the fuel rail assembly before removal. The fittings should be capped to prevent dirt from entering open lines.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove the intake manifold plenum.
  6.  
  7. Remove the distributor.
  8.  
  9. Disconnect the fuel lines at the rail.
  10.  
  11. Unfasten the fuel pipe bracket bolt.
  12.  
  13. Remove the fuel inlet and return line O-rings and discard them.
  14.  
  15. Unplug the fuel injector electrical connectors and remove them from the coil bracket.
  16.  
  17. Unfasten the fuel rail retaining bolts.
  18.  
  19. Disconnect the vacuum line to the fuel pressure regulator.
  20.  
  21. Remove the fuel rail.
  22.  
  23. Remove the O-rings seals and backups from the injectors. Discard the old seals but retain the backups for reuse.
  24.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the fuel rail assembly-MFI systems

To install:

Ensure that the O-ring backups are on the injectors before installing the O-rings. Lubricate the O-rings with clean engine oil before installation.

  1. Install the fuel rail in the intake manifold. Tilt the fuel rail assembly to install the injectors. Tighten the fuel rail retaining bolts to 89 inch. lbs. (10 Nm).
  2.  
  3. Attach the injector electrical connectors.
  4.  
  5. Install new O-rings on the fuel pipes.
  6.  
  7. Install the fuel return and feed lines.
  8.  
  9. Tighten the fuel pipe nuts to 20 ft. lbs. (27 Nm) using a back-up wrench to prevent the fittings from turning.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks.
  14.  
  15. Install the intake manifold plenum.
  16.  

 
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