Alero, Grand Am 1999-2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.2L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner outlet resonator.
  4.  
  5. Disconnect the vacuum pipe from the fuel pressure regulator.
  6.  
  7. Remove the engine fuel supply and return pipes.
  8.  
  9. Disconnect the fuel injector harness connectors.
  10.  
  11. Remove the fuel rail attaching studs.
    WARNING
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

  12.  
  13. Remove the fuel rail using the following procedure:
  14.  
  15. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
  16.  
  17. Rotate the fuel rail in order to position the injectors downward.
  18.  
  19. Remove the fuel rail.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail mounting

  20.  
  21. Remove the fuel injectors. Refer to the Fuel Injector Procedure.
  22.  

To install:

  1. Install the fuel injectors.
    NOTE
    Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  2.  
  3. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  4.  
  5. Align the injectors by rotating the fuel rail forward.
  6.  
  7. Carefully push the fuel injectors into the cylinder head ports.
  8.  
  9. Install the fuel rail attaching studs. Tighten the fuel rail studs to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
  12.  
  13. Install the fuel supply and return pipes.
  14.  
  15. Connect the vacuum pipe to the fuel pressure regulator.
  16.  
  17. Install the air cleaner outlet resonator.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF .
    6.  
    7. Inspect for fuel leaks.
    8.  

  22.  

2.4L Engine
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the air cleaner outlet duct clamp.
  6.  
  7. Remove the air cleaner outlet duct from the air cleaner resonator.
  8.  
  9. Loosen the air cleaner resonator clamp at the throttle body.
  10.  
  11. Remove the bolts securing the resonator.
  12.  
  13. Remove the resonator from the throttle body.
  14.  
  15. Remove the crankcase vent hose to bottom of the resonator, then extract the resonator.
  16.  
  17. Label and disconnect the fuel pressure regulator vacuum hose.
  18.  
  19. Remove the fuel rail bolts.
  20.  
  21. Remove the electrical connector from the camshaft position sensor.
  22.  
  23. Label and unplug all injector harness connectors. Push in the wire connector clip while pulling the connector away from the injector.
  24.  
  25. Remove the fuel inlet pipe at the rail. Use a back-up wrench on the fuel rail inlet fitting to prevent it from turning.
  26.  
  27. Carefully lift the rail from the cylinder head. Discard the injector O-rings.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail and pressure regulator assembly-2.4L engine

  28.  

To install:


NOTE
Whenever the fuel rail is disconnected from the fuel pipes, reconnect the fuel pipes to the rail at this time. Apply a few drops of clean engine oil to the male end of the fuel pipes before installing.

  1. Install the fuel pipe into the regulator. align the bracket to retain the return pipe. Tighten the bracket screw to 53 inch lbs. (6 Nm). Use a back-up wrench on the fuel rail inlet fitting to prevent it turning. Tighten the inlet pipe nut to 22 ft. lbs. (30 Nm).
    NOTE
    When ever there is not enough threadlocking material on the threads of the fuel outlet pipe bracket screw, apply Loctite® 262 to insure proper locking.

  2.  
  3. Rotate the fuel injectors as required to avoid stretching the wiring harness.
  4.  
  5. Position the fuel rail over the cylinder head and connect the fuel injector electrical wiring. Place the fuel trail assembly into the cylinder head. Secure the retaining bolts to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the vacuum hose to the fuel pressure regulator.
  8.  
  9. If the front engine fuel pipes are being replaced, install a new O-rings and coat them with clean engine oil.
    NOTE
    Use a back-up wrench to prevent the female fitting from turning.

  10.  
  11. Install the inlet and return pipe connections. Tighten the fuel pipe fittings to 20 ft. lbs. (27 Nm).
  12.  
  13. Install and secure the fuel pipe bracket clamp bolt to 106 inch lbs. (12 Nm).
  14.  
  15. Apply a few drops of clean engine oil to the vent hose and attach it to the bottom of the air cleaner resonator.
  16.  
  17. Apply a few drops of engine oil to the air cleaner resonator before installing it to the throttle body. Tighten the resonator clamp to 35-44 inch lbs. (4-5 Nm).
  18.  
  19. Install the air cleaner resonator bolts and secure to 89 inch lbs. (10 Nm).
  20.  
  21. Attach the air cleaner outlet duct to the resonator and tighten the duct clamp to 35-44 inch lbs. (4-5 Nm).
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Inspect the system for fuel leaks throughout the following steps:
    1. Turn the ignition switch to the ON position for two seconds.
    2.  
    3. Turn the ignition switch to the OFF position for ten seconds.
    4.  
    5. Turn the ignition switch to the ON position.
    6.  
    7. Check for fuel leaks.
    8.  

  26.  

3.1L Engine
  1. Disconnect the negative battery cable, then properly relieve the fuel system pressure.
  2.  
  3. Remove the intake manifold plenum (upper intake manifold) as outlined in Section 3.
  4.  
  5. Unfasten the fuel pipe bracket bolt, then remove the fuel pipes at the rail.
  6.  
  7. Remove the fuel pressure regulator from the rail.
  8.  
  9. Remove and discard the fuel feed and return pipe O-rings.
  10.  
  11. Detach the fuel injector electrical connectors.
    NOTE
    Be careful when removing the fuel rail assembly to avoid damage to the injector electrical connector terminals and spray tips. Prevent dirt and other debris from entering open lines and passages. Fittings should be capped and holes should be plugged during servicing.

  12.  
  13. If applicable, disconnect the coolant temperature sensor wiring.
  14.  
  15. Unfasten the fuel rail retaining bolts, then remove the rail assembly from the engine.
  16.  
  17. Remove and discard the injector O-ring seals from the spray tip end of each injector. With the O-rings removed, the O-ring backup may slip off the injector. Keep the backup for reuse during installation.

    Click image to see an enlarged view

    Fig. View of the fuel rail assembly, injectors and fuel pressure regulator-3.1L engine

  18.  

To install:

  1. Make sure the backups are on the injectors, then lubricate new injector O-rings with clean engine oil and install on the spray tip of each injector.
  2.  
  3. Install the fuel rail in the intake manifold. Tilt the assembly to install the injectors. Secure with the retaining bolts, then tighten the bolts to 7 ft. lbs. (10 Nm).
  4.  
  5. Attach the injector electrical connectors.
  6.  
  7. Put new O-rings on the fuel feed and return pipes, then install the pipes. Using a backup wrench on the fittings to prevent them from turning, tightening the fuel pipe nuts to 13 ft. lbs. (17 Nm).
  8.  
  9. Install any remaining components.
  10.  
  11. Connect the negative battery cable, then tighten the fuel filler cap.
  12.  
  13. Turn the ignition to the ON position for two seconds, then turn it to the OFF position for ten seconds. Turn again to the ON position and check for fuel leaks.
  14.  
  15. Install the intake manifold plenum.
  16.  

3.4L Engine

NOTE
An eight digit identification number is stamped on the left hand fuel rail, fueling even cylinders 2, 4, 6. Refer to this number if servicing or part replacement is required.


CAUTION
In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.


NOTE
Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

  1. Relieve the fuel system pressure.
  2.  
  3. Remove the upper intake manifold, as outlined in the Engine Mechanical Section.
  4.  
  5. Remove the engine compartment fuel pipe retainer bolt.
  6.  
  7. Disconnect the engine fuel feed pipe at the fuel rail.
  8.  
  9. Disconnect the engine fuel return pipe at the fuel pressure regulator.
  10.  
  11. Remove the fuel feed pipe and fuel return pipe O-rings and discard.
  12.  
  13. Disconnect the main injector harness electrical connector.
  14.  
  15. Disconnect the connectors from the fuel injectors, as follows:
    1. Pull up the lock release (2) of the fuel injector connector.
    2.  
    3. Depress the lock tab (1) and lift the connector from the injector.

      Click image to see an enlarged view

      Fig. Detach the fuel injector connectors by pulling up on the lock release (2), then depress the lock tab (1) and lift the connector from the injector

    4.  

  16.  
  17. Remove the injector harness from the fuel rail.
  18.  
  19. Disconnect the coolant temperature sensor electrical connector.
  20.  
  21. Remove the fuel rail attaching bolts.
  22.  
  23. Remove the fuel rail assembly.
  24.  
  25. Remove the injector O-ring seal from the spray tip end of each injector. Discard the seals.
  26.  

To install:


NOTE
Note the following:



Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
 
Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
 
Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

Click image to see an enlarged view

Fig. Exploded view of the fuel rail mounting

 

  1. Install the fuel rail assembly into the intake manifold. Tilt the rail assembly to install the injectors.
  2.  
  3. Install the fuel rail attaching bolts. Tighten the fuel rail attaching bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Connect the coolant temperature sensor electrical connector.
  6.  
  7. Install the injector electrical harness to the fuel rail.
  8.  
  9. Connect the injector electrical connectors. Push the slide locks (2) into the locked position.
  10.  
  11. Connect the main injector harness electrical connector.
  12.  
  13. Install the new O-rings on the fuel feed pipe and fuel return pipe.
  14.  
  15. Connect the fuel feed pipe to the fuel rail. Tighten the fuel feed pipe fitting to 13 ft. lbs. (17 Nm).
  16.  
  17. Connect the fuel return pipe to the fuel pressure regulator. Tighten the fuel return pipe fitting to 13 ft. lbs. (17 Nm).
  18.  
  19. Install the engine compartment fuel pipe retainer bolt. Tighten the fuel pipe retainer bolt to 18 ft. lbs. (25 Nm).
  20.  
  21. Install the upper intake manifold.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF .
    6.  
    7. Inspect for fuel leaks.
    8.  

  26.  

 
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