Pulling Fuel Rails and Injectors - ZR-1 Net Registry Forums

KJL · 08-13-2013

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

Quote:

Originally Posted by KJL

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

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.

oricale · 08-13-2013

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

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

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.

KJL · 08-13-2013

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.

KJL · 08-14-2013

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

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.

KJL · 08-14-2013

Yes, I have checked the bag names several times and they are not there. Perhaps they are not part of the Viton kit.

08-13-2013	#1
KJL Join Date: Mar 2013 Location: Roswell, GA Posts: 234	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.

08-13-2013	#3
vilant Join Date: Jun 2012 Location: PA Posts: 772	Re: Pulling Fuel Rails and Injectors 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. __________________ Joe 1990 Bright Red ZR-1 #2599

08-13-2013	#4
oricale Join Date: Oct 2011 Location: STAFFORD VA, Posts: 576	Re: Pulling Fuel Rails and Injectors 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 __________________ [B][I][COLOR=red]1990 ZR1[/COLOR][COLOR=black] [U]#00077 [COLOR=red]RED[/COLOR]/[COLOR=red]RED[/COLOR] (10Y022 PEP CAR) [/U][/COLOR][/I][/B][B][I][COLOR=red]1991 ZR1[/COLOR][COLOR=black] [U]#00517 ("Irene")[COLOR=red]WHITE[/COLOR]/[COLOR=red]RED-SOLD:cry:[/COLOR] [B][/B] [/U][/COLOR][/I][/B][B][I][COLOR=red]1992 ZR1[/COLOR][COLOR=black] [U]#00445("The Revenant")[COLOR=red][COLOR="Black"]BLACK [/COLOR][/COLOR]/[COLOR=red]RED(2016 T.O.D!) [/COLOR] [/U][/COLOR][/I][/B] [B][I][COLOR=red]2009 [COLOR=red]Z06!![COLOR=black]BLK/BLK rare Linen interior[/COLOR] 707HP!![/COLOR] [/COLOR][/I][/B] [B][I][COLOR=red]2006[/COLOR] BLK/BLK Z51 (Just SICK FAST!)SOLD)[/I][/B] [B][I]1996 BLK/BLK LT4 Grnsprt(sold...Twice!)[/I][/B] [B][I]1991 RED/REDL98(Fell off the shipping truck:([/I][/B] [B][I]1980 BLK/RED L82(Sold)[/I][/B] [B][I][B][I]1990[/I][/B] RED/BLK(sold.....In Japan)[/I][/B] [I][COLOR=black][B][I]2006[/I][/B][/COLOR][/I] [COLOR=red]Mustang GT[/COLOR] ([B][I]mach 1[/I][/B])[B](sold)[/B] [COLOR=black][B][I]1969[/I][/B][/COLOR] [COLOR=red]Mach[/COLOR] [B][I]1(sold in Japan)[/I][/B] [COLOR=black][B][I]1969[/I][/B][/COLOR] [COLOR=red]Mach[/COLOR] [B][I]1#2(sold)[/I][/B] [B][I]WAZOO Member...[/I][/B] [url]www.evolution-motorsport.com[/url] facebook/evolutionmotorsportengineering Your Local [url]www.Amsoil.com[/url] dealer/user.. Victory Loves Preparation

08-13-2013	#5
Franke Join Date: May 2013 Location: Beaver, PA Posts: 516	Re: Pulling Fuel Rails and Injectors 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.

08-13-2013	#6
Dynomite Join Date: Aug 2009 Location: South Dakota/California Posts: 3,797	Re: Pulling Fuel Rails and Injectors 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. __________________ Left Clickable links -Solutions- LT5 Modifications/Rebuild Tricks Low Mileage ZR-1 Restoration 1990 Corvette (L98) Modifications LT5 Eliminated Systems LT5 Added Systems LT5/ZR-1 Fluids 1995 LT5 SPECIFIC TOP END REBUILD TRICKS

08-14-2013	#8
KJL Join Date: Mar 2013 Location: Roswell, GA Posts: 234	Re: Pulling Fuel Rails and Injectors 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?? __________________ 1995 ZR1 #159 Ported,Corsa,4.10 Rear, Dual Disc RAM Clutch, Alum Flywheel, Haibeck Chip, ZFDoc Plates, Relocated Battery 400 rwhp 1992 ZR1 #280 Ported, Locked Secondary's, Flowmaster Exhaust, Haibeck Chip, 375rwhp 1996 Collectors LT4 (Stock) 1972 Convertible 434 Small Block 572 rwhp