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Fuel Rail & Injectors: Removal

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE (GASOLINE) .
  2. Disconnect the engine fuel pipes from the engine fuel flex hoses. See FUEL LINE QUICK CONNECT FITTINGS .
  3. Use a back up wrench on the fuel pressure regulator and disconnect the return line.
  4. Disconnect the fuel feed line from the fuel rail.
  5. Remove the engine fuel pipes fasteners located on the engine. See Figure.
  6. Remove the engine fuel supply and return pipes.
  7. Remove the air cleaner outlet resonator.
  8. Disconnect the vacuum pipe from the fuel pressure regulator. See Figure.
  9. Remove the retaining bolt from the fuel pressure regulator.
  10. Remove the fuel pressure regulator. See Figure.
  11. Disconnect the fuel injector harness connectors.
  12. Remove the fuel rail attaching studs. See Figure.
  13. Remove the fuel rail using the following procedure:
    • Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    • Rotate the fuel rail to position the injectors downward.
    • Remove the fuel rail.
  14. Remove the fuel injector retainer clip. See Figure.
  15. Remove the fuel injectors from the fuel rail. See Figure.
    16. CAUTION: Visually inspect the fuel injector to determine if the upper "O" ring was also removed. If the upper "O" ring in not removed, remove the "O" ring from the fuel rail assembly.
    CAUTION: If the fuel injector insulator cups are removed from the cylinder head while removing the fuel rail, NEW insulator cups must be installed.
  16. Remove and discard the fuel injector "O" rings.
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