For 1990-2009 cars

## Fuel Injection Fuel Rail Assembly Replacement SOHC

### Removal Procedure

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Important: When servicing the fuel rail assembly, be careful to prevent dirt and other contaminants from entering the fuel passages. Fittings should be capped and holes plugged during servicing. Before removal, the fuel rail may be cleaned with a spray type engine cleaner such as AC Delco X-30A, or equivalent, following package instructions. Do not soak rails in liquid cleaning solvent.

1. Disconnect the negative battery terminal.
2. Remove the air intake tube, air filter cover, and fresh air tube.
3. Remove the positive crankcase ventilation (PCV) hose.

Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

4. Relieve the pressure in the fuel system at the fuel pressure test port. Refer to Fuel Pressure Relief .
5. Remove the fuel feed line retainer clip attachment nut, 10 mm hex.

Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

6. Disconnect the fuel supply line by compressing the 2 plastic retainer tabs and pulling on the fuel supply line. Remove and discard the plastic retainer.
7. Remove the accelerator control cable bracket bolts. Disconnect the cable from the throttle lever and lay it over the intake manifold.
8. Disconnect the injector electrical connectors.

8.1. | Pull pop up CPA. It is not necessary to remove the CPA from the connector.

8.2. | Squeeze the connector at the CPA.

8.3. | Pull to remove.

9. Remove the fuel rail assembly attachment bolts.

Notice: Use care in removing the fuel rail assembly to prevent damage to the electrical connector terminals and spray tips. The fuel injector is serviced as a complete assembly only. Support fuel after fuel rail is removed in order to avoid damaging fuel rail components. Since it is electrical, it should not be immersed in any cleaner.

Important: Enough space exists between the intake manifold and cam cover to remove the fuel rail as an assembly.

10. Remove the fuel rail assembly.

10.1. | Carefully pull the rail back and upward to remove the injectors from the intake manifold ports.

10.2. | Move the rail back against the intake manifold runners.

10.3. | Rotate the rail so the injectors point upward.

10.4. | Move the rail against the power steering pump.

10.5. | Lift the #1 injector and remove the rail from between the cylinder head and intake manifold.

Important: Whenever the fuel rail is removed for service, the injectors must be removed and the upper and lower injector O-rings must be replaced.

11. Remove the clips retaining the fuel injectors and pull the injectors out of the rail.
12. Disassemble the injector O-ring seals from each injector using a special seal removal tool or brass seal pick and discard.

### Installation Procedure

Notice: When cleaning or servicing the fuel rail, care must be taken to assure that the plastic fuel rail surfaces that mate to the injector O-rings are not scratched.

1. Lubricate the new O-ring seals with clean engine oil and install the injectors into the fuel rail.
2. Install fuel rail assembly to intake manifold.
3. With the injectors pointing upward, lower the fuel rail into the cavity between the cam cover and intake manifold.
4. Move the rail towards the power steering pump.
5. Rotate the injectors into a horizontal position. The fuel rail must be placed against the intake manifold runners to accomplish this.
6. Align the injectors with their respective port holes.
7. Carefully push the fuel injectors into holes, making sure they have seated on the intake manifold.

Notice: Refer to Fastener Notice in the Preface section.

8. Install the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attachment bolts 12 N·m (9 lb ft).

9. Connect the fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.
10. Connect the accelerator cable to the throttle body and to the accelerator cable support bracket. Attach the accelerator control cable bracket.

Tighten
Tighten the accelerator control cable bracket-to-intake manifold (L24) to 30 N·m (22 lb ft).

11. Connect the PCV valve hose.

Notice: Lubricate with clean engine oil the male end of the fuel rail that connects with the fuel supply line. Firmly press on the female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

Notice: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

12. Lubricate the male fuel feed line connection with clean engine oil. Attach the fuel feed line and pull back to confirm engagement.
13. Install the fuel line retainer clip attachment screw, 10 mm hex.

Tighten
Tighten the fuel line retainer clip attachment screw to 4 N·m (35 lb in).

14. Connect the negative battery terminal.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

15. Prime the fuel system.

15.1. | Cycle ignition ON for 5 seconds and then OFF for 10 seconds.

15.2. | Repeat step 10.1 twice.

15.3. | Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.

15.4. | If engine does not start, repeat steps 10.1-10.3 in Removal Procedure.

16. With the engine OFF and the ignition ON, pressurize the fuel system and check for leaks.
17. Install the intake tube and air filter cover.

## Fuel Injection Fuel Rail Assembly Replacement DOHC

### Removal Procedure

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Important: When servicing the fuel rail assembly, be careful to prevent dirt and other contaminants from entering the fuel passages. Fittings should be capped and holes plugged during servicing. Before removal, the fuel rail may be cleaned with a spray type engine cleaner such as AC Delco X-30, or equivalent, following package instructions. Do not soak rails in liquid cleaning solvent.

1. Disconnect the negative battery terminal.
2. Remove the air intake tube and fresh air tube.
3. Remove the throttle cable.
4. Remove the power steering support bracket.

Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
6. Remove the attachment nut, 10 mm hex, holding the fuel feed line clip to the intake manifold brace.

Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

7. Disconnect the fuel supply line by compressing the two plastic retainer tabs and pulling on the fuel supply line. Remove and discard the plastic retainer.
8. Disconnect the injector electrical connectors.

8.1. | Pull pop up CPA. It is not necessary to remove the CPA from the connector.

8.2. | Squeeze the connector at the CPA.

8.3. | Pull to remove.

9. Remove the fuel rail assembly attachment bolts.

Notice: Use care in removing the fuel rail assembly to prevent damage to the electrical connector terminals and spray tips. The fuel injector is serviced as a complete assembly only. Support fuel after fuel rail is removed in order to avoid damaging fuel rail components. Since it is electrical, it should not be immersed in any cleaner.

10. Remove the fuel rail assembly. Carefully pull the rail back and upward to remove the injectors from the intake manifold ports.

Important: Whenever the fuel rail is removed for service, the injectors must be removed and upper and lower injector O-rings must be replaced.

11. Remove the clips retaining the fuel injectors and pull the injectors out of the rail.
12. Disassemble the injector O-ring seals from each injector using a special seal removal tool or brass seal pick and discard.

### Installation Procedure

Notice: When cleaning or servicing the fuel rail, care must be taken to assure that the plastic fuel rail surfaces that mate to the injector O-rings are not scratched.

1. Lubricate the new O-ring seals with clean engine oil and install the injectors into the fuel rail.
2. With the injectors pointing downward, install the fuel rail assembly to the intake manifold by lowering the fuel line end of the fuel rail into the cavity between the cam cover and intake manifold.

Notice: Refer to Fastener Notice in the Preface section.

3. Apply LOCTITE 242® Threadlocker (GM P/N 21485277) or equivalent to the attachment bolt threads. Install the fuel rail attachment bolts.

Tighten
Tighten the fuel rail attachment bolts to 12 N·m (9 lb ft).

Notice: Rotate #2 injector terminals approximately 15° from vertical towards the front of the engine. This will provide clearance between the throttle cable and #2 injector wires. Clearance is necessary to prevent abrasion of wires.

4. Connect the fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.
5. Install the power steering support bracket.

Tighten
Tighten the power steering pump brace-to-block to 30 N·m (22 lb ft).

6. Connect the accelerator cable to the throttle body and to the accelerator cable support bracket. Attach the accelerator control cable bracket.

Tighten
Tighten the accelerator control cable to 30 N·m (22 lb ft).

Notice: Lubricate with clean engine oil the male end of the fuel rail that connects with the fuel supply line. Firmly press on the female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

Notice: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

7. Lubricate the male fuel feed line and male fuel return line connections with clean engine oil. Attach the fuel feed line and pull back to confirm engagement. Attach the fuel return line and pull back to confirm engagement.
8. Install the fuel line clip to the bracket with the attachment bolt, 10 mm hex.

Tighten
Tighten the fuel line retainer clip to 4 N·m (35 lb in).

9. Connect the negative battery terminal.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

10. Prime the fuel system.

10.1. | Cycle ignition ON for 5 seconds and then OFF for 10 seconds.

10.2. | Repeat step 10.1 twice.

10.3. | Crank the engine until it starts. The maximum starter motor cranking time is 15 seconds.

10.4. | If the engine does not start, repeat steps 10.1-10.3.

11. With the engine OFF and the ignition ON, pressurize the fuel system and check for leaks.
12. Install the air tube and air filter cover.