View Full Version : Pulling Fuel Rails and Injectors
In the process of replacing injector housing to head gaskets. I have the intake plenum off and in the process of removing fuel rails and injectors.
Can I just remove the wire harness and disconnect the fuel rail cross over tubing and remove injector housing with injectors and fuel rail installed?
If not, what is the best way to remove injectors and rails? I attempted to lift the rail and injectors as a unit but they seem fairly well "stuck" in the injector housing. I didn't want to force anything because I know how that will end.
secondchance
08-13-2013, 10:48 PM
In the process of replacing injector housing to head gaskets. I have the intake plenum off and in the process of removing fuel rails and injectors.
Can I just remove the wire harness and disconnect the fuel rail cross over tubing and remove injector housing with injectors and fuel rail installed?
If not, what is the best way to remove injectors and rails? I attempted to lift the rail and injectors as a unit but they seem fairly well "stuck" in the injector housing. I didn't want to force anything because I know how that will end.
It is unnerving to pull injectors and fuel rail out of IH for the first time. You can pull injectors mounted on the fuel rail. I think I used screw driver wrapped in rag and found a spot can use as a fulcrum to pry the rail starting from the front (number 1 and 3 cylinders).
vilant
08-13-2013, 10:53 PM
I used a pry bar and rags but it wouldn't budge. So I pulled the retaining clips off of each injector and the rail came off easy. Forgot there was still gas in the rail though and it got all over, so have plenty rags around if you do that way. My injectors were just about glued in there after 22 years. Had to work each one out individually, PIA.:cheers:
oricale
08-13-2013, 10:54 PM
Hello!,..yes if you need to pull the fuel rails,..just get a large screw driver and gently pry them up. they will pop right out...I would suggest replacing the seals for the injectors as well, unless they are in excellent condition. Its one of those things that you can regret later.
Make sure you clean the mating portions of the IH's and Heads,..the best thing to use is a plastic putty knife and brake cleaner.
Dempsey
Franke
08-13-2013, 11:14 PM
Don't forget to cover the open plenum ports etc with something to keep dirt out when cleaning around the port holes. I put clean rags in each hole. Dont want to loose any parts or get dirt in there. I would definately replace the injector seals. Jerrys gaskets has them. I think he has some that handle ethanol fuel better too.
Dynomite
08-13-2013, 11:22 PM
And.....open the fuel tank cap or the fuel lines might continue leaking fuel all over the floor and Z......at least mine did untill I loosened the fuel cap.
Thanks for the tips. I have the Viton o-ring seals from Jerry's. I plan on replacing all the fuel line o-rings while I am at it. I hope this cures the pesky injector plenum to head leakage issue. I hoped re-torquing would have fix it but oil still keeps weeping through the gasket. My guess is the old gasket was reused when the housing was removed for powder coating.
Next question, I lifted the injectors and noticed the primary injectors do not have an o-ring on the injector itself but it appears the injector housing has an o-ring or some kind of seal within the bore. The Jerry's seal kit does not appear to have a replacement seal for this??
Franke
08-14-2013, 11:13 AM
You are correct. The seals are in the bore and can be pried out carefully with a small tool so as not to damage them if reused. When I bought Jerrys gaskets I got a separate bag with seals for the primaries. Are you sure you don't have them? My injectors came with seals also but I used Jerrys.
Yes, I have checked the bag names several times and they are not there. Perhaps they are not part of the Viton kit.
There is something odd going on that will need some clarification and/or photos.
1. Your signature indicates you have a 1995 ZR-1
2. Only 1990~92 models have the seal in the injector housing for the primary injector.
3. 1993~1995 LT5 engines have the same o-ring seal on both the top & bottom of all 16 injectors.
If your injector housings have an o-ring seal in the primary injector bore, then you have either early injector housings on a late model engine (replaced at some point after manufacture) or the engine has been replaced with a 90~92 model.
You ordered the 93~95 pkg which would not include the lower seal for the primary injector, PN 10067600-V.
A note regarding re-use of original fuel system seals
I am opposed to re-using the original o-ring seals, especially in the fuel system, regardless of how careful one is or how good they might appear to be. I have never been able to determine what material the original seals were made from, so compatibility with modern, ethanol blended gasoline is questionable. Regardless of the compatibility issue, original seals are now at least 19 years old. The seals take a "set" and also do not have the compressibility as when new. For the small difference in expense, it's simply not worth it to risk a fuel leak or trying to hunt down an difficult vacuum leak (in the case of the lower injector seal).
Wow, OK, it looks like I need to do some checking. I guess the first question to ask is are they interchangeable? I noticed looking into the injector bores, they don't line up well with the heads. It is not a smooth transition between the injector housing and the head. There is a "shelf".
How do I identify the engine as being a 95? I know I have the Dunn heads on each side. Not sure if that means anything.
Perhaps I should start a new thread to get to the bottom of this. I will also contact the previous owner.
Wow, OK, it looks like I need to do some checking. I guess the first question to ask is are they interchangeable? I noticed looking into the injector bores, they don't line up well with the heads. It is not a smooth transition between the injector housing and the head. There is a "shelf".
How do I identify the engine as being a 95? I know I have the Dunn heads on each side. Not sure if that means anything.
Perhaps I should start a new thread to get to the bottom of this. I will also contact the previous owner.
This is your thread and the question you ask are relative in my opinion, so using this thread is appropriate.
Here is a link to an article I wrote regarding the different styles of Injector Housings, that you can download for free. It will allow you to identify exactly which injector housings are on your LT5.
http://jerrysgaskets.com/store2/root/index.php?main_page=product_info&cPath=13&products_id=762
Dunn heads were ONLY installed on some 94(very few)~95 engines. The most definitive way to determine 90~92 375hp from 93~95 405hp engines is to look at the bottom, LH driver side) corner of the front cover.
Here are links to the gaskets so you can see the difference.
http://jerrysgaskets.com/store2/root/index.php?main_page=product_info&cPath=18&products_id=14
http://jerrysgaskets.com/store2/root/index.php?main_page=product_info&cPath=18&products_id=15
The gasket photo for the 405 hp is reversed as viewed from the front of the engine, but you get the idea, curved (early), vs square (late).
Thanks for the great info. Regardless of outcome, do you sell just the injector seals for the housing? It appears the housing to head and plenum gaskets for 95 that I already purchased should work?
This is an odd situation, so let's make absolutely sure what your situation is before ordering new seals. Review the Tech Data & confirm which housings you have. If you are still unsure, post a photo here or email to store@jerrysgaskets.com.
That is a good idea. I did some thread checking on the corvette forum from the person I purchased the car from and confirmed he used older model injector housing and plenum for powder coating purposes. I will check the engine out when I get home and also the part numbers.
Funny, the numbers on the housing do not match any of the numbers in the article but very close to number in housing picture for the 2nd design 1991 housing. My number is 10135836. The number in the picture looks to be 10135837, probably the other side.
I wonder why these numbers are not listed. Anyway I am certain it is an earlier version and the cover has the squared bottom corners.
The attached photo shows the shelf I spoke of earlier. I would have expected a better port match. Maybe it is not important as long as the injector housing port is bigger than the head port. It shows that fuel/oil collects on this shelf and that is what is seeping through the gasket and onto the head. It only happens when the car sits.
The other attachment is an inside view of IH.
vBulletin® v3.8.11, Copyright ©2000-2025, vBulletin Solutions Inc.