Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo, Regal 2001-2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



3.1L And 3.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Upper intake manifold
     
    Fuel inlet and return lines
     
    Fuel injector electrical connectors
     
    Coolant temperature sensor electrical connector
     
    Fuel rail
     
    Fuel injector retaining clips
     
    Fuel injectors

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector-3.1L and 3.4L engines

     

  6.  

To install:

  1. Coat the new fuel injector O-rings with clean engine oil.
  2.  
  3. Install or connect the following:

    Lower backup O-ring
     
    Upper O-ring
     
    Lower O-ring
     
    Fuel injector
     
    Fuel injector retaining clips
     
    Fuel rail and torque the bolts to 7 ft. lbs. (10 Nm)
     
    Coolant temperature sensor electrical connector
     
    Fuel injector electrical connectors
     
    Fuel inlet and return lines with new O-rings and torque the fittings to 13 ft. lbs. (17 Nm)
     
    Upper intake manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Upper intake manifold
     
    Fuel inlet and return lines
     
    Fuel injector electrical connectors
     
    Coolant temperature sensor electrical connector
     
    Fuel rail
     
    Fuel injector retaining clips
     
    Fuel injectors

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector-3.4L engines

     

  6.  

To install:

  1. Coat the new fuel injector O-rings with clean engine oil.
  2.  
  3. Install or connect the following:

    Lower backup O-ring
     
    Upper O-ring
     
    Lower O-ring
     
    Fuel injector
     
    Fuel injector retaining clips
     
    Fuel rail and torque the bolts to 7 ft. lbs. (10 Nm)
     
    Coolant temperature sensor electrical connector
     
    Fuel injector electrical connectors
     
    Fuel inlet and return lines with new O-rings and torque the fittings to 13 ft. lbs. (17 Nm)
     
    Upper intake manifold and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

3.5L And 3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Fuel injector sight shield
     
    Fuel feed and return lines
     
    Fuel pressure regulator vacuum connection
     
    Ignition coil wires from the coil
     
    Fuel injector electrical connectors
     
    Fuel rail
     
    Fuel injector retaining clips
     
    Fuel injectors
     

  6.  

To install:

  1. Coat the new fuel injector O-rings with clean engine oil.
  2.  
  3. Install or connect the following:

    Lower backup O-ring
     
    Upper O-ring
     
    Lower O-ring
     
    Fuel injector
     
    Fuel injector retaining clips
     
    Fuel rail and torque the bolts to 7 ft. lbs. (10 Nm) if equipped with bolt retainers. If equipped with snap-lock tab retainers, push down until the retainers snap into place.
     
    Fuel injector electrical connectors
     
    Ignition coil wires to the coil
     
    Fuel pressure regulator vacuum connection
     
    Fuel feed and return lines
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  
  7. Install the fuel injector sight shield and torque the nuts to 27 inch lbs. (3 Nm).
  8.  

3.5L, 3.8L & 3.9L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Fuel injector sight shield
     
    Fuel feed and return lines
     
    Fuel pressure regulator vacuum connection
     
    Ignition coil wires from the coil
     
    Fuel injector electrical connectors
     
    Fuel rail
     
    Fuel injector retaining clips
     
    Fuel injectors
     

  6.  

To install:

  1. Coat the new fuel injector O-rings with clean engine oil.
  2.  
  3. Install or connect the following:

    Lower backup O-ring
     
    Upper O-ring
     
    Lower O-ring
     
    Fuel injector
     
    Fuel injector retaining clips
     
    Fuel rail and torque the bolts to 7 ft. lbs. (10 Nm) if equipped with bolt retainers. If equipped with snap-lock tab retainers, push down until the retainers snap into place.
     
    Fuel injector electrical connectors
     
    Ignition coil wires to the coil
     
    Fuel pressure regulator vacuum connection
     
    Fuel feed and return lines
     
    Negative battery cable
     

  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  
  7. Install the fuel injector sight shield and torque the nuts to 27 inch lbs. (3 Nm).
  8.  

5.3L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the following electrical connectors:

    EVAP purge solenoid
     
    Manifold absolute pressure (MAP) sensor
     
    Electronic throttle control (ETC)
     
    Oil pressure sensor
     
    Valve lifter oil manifold
     

  8.  
  9. Disconnect the generator electrical connector.
  10.  
  11. Remove the connector position assurance (CPA) retainer.
  12.  
  13. Disconnect the main ignition coil harness electrical connector.
    NOTE
    Mark the injector connectors to their corresponding injectors to ensure correct reassembly.

  14.  
  15. Disconnect the fuel injector electrical connectors.
  16.  
  17. Remove the CPA retainer.
  18.  
  19. Disconnect the main ignition coil harness electrical connector.
    NOTE
    Mark the injector connectors to their corresponding injectors to ensure correct reassembly.

  20.  
  21. Disconnect the fuel injector electrical connectors.
  22.  
  23. Remove the engine wiring harness retainers from the tabs on the fuel rail.
  24.  
  25. Reposition the harness out of the way.
  26.  
  27. Disconnect the fuel feed and EVAP lines.
  28.  
  29. Note the location of the fuel rail ground strap.
  30.  
  31. Remove the intake manifold bolt and ground strap.
  32.  
  33. Remove the fuel rail bolts.
  34.  
  35. Remove the fuel rail with injectors. Lift evenly on both sides of the fuel rail until all injectors have been removed from their bores.
    NOTE
    Do not separate the fuel injectors from the fuel rail unless component service is required.

  36.  
  37. Remove the fuel injector retaining clip, as required.
  38.  
  39. Remove the fuel injector, as required
  40.  
  41. Remove and discard the fuel injector O-ring seals, as required.

    Click image to see an enlarged view

    Fig. Fuel rail and injectors-5.3L engine

  42.  

To install


NOTE
Do not reuse the fuel injector O-ring seals. Install NEW O-ring seals during assembly.

  1. Note the installed location of the fuel rail ground strap.
  2.  
  3. Lubricate the NEW O-ring seals with clean engine oil.
  4.  
  5. Install the NEW fuel injector O-ring seals (532, 534) onto the injector, as required.
  6.  
  7. Install the fuel injector (533), as required
  8.  
  9. Install the fuel injector retaining clip (521), as required.
  10.  
  11. If necessary, lubricate the NEW O-ring seals with clean engine oil.
  12.  
  13. If necessary, install NEW O-ring seals to the fuel injectors.
  14.  
  15. Install the fuel rail (510) with injectors. Push firmly on both sides of the rail until all the injectors have been seated into their bores.
  16.  
  17. Apply a 0.2 in. (5mm) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the fuel rail bolts.
  18.  
  19. Install the fuel rail bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  20.  
  21. Install the ground strap and intake manifold bolt. Tighten the bolt to 89 inch lbs. (10 Nm).
  22.  
  23. Connect the fuel feed and EVAP lines.
  24.  
  25. Position the harness to the engine. Install the engine wiring harness retainers to the tabs on the fuel rail.
    NOTE
    Install the marked injector connectors to their corresponding injectors.

  26.  
  27. Connect the fuel injector electrical connectors.
  28.  
  29. Connect the main ignition coil harness electrical connector.
  30.  
  31. Install the CPA retainer.
    NOTE
    Install the marked injector connectors to their corresponding injectors.

  32.  
  33. Connect the fuel injector electrical connectors.
  34.  
  35. Connect the main ignition coil harness electrical connector.
  36.  
  37. Install the CPA retainer.
  38.  
  39. Connect the generator electrical connector.
  40.  
  41. Connect the following electrical connectors:

    EVAP purge solenoid
     
    MAP sensor
     
    ETC
     
    Oil pressure sensor
     
    Valve lifter oil manifold
     

  42.  
  43. Install the air cleaner outlet duct.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Use the following steps to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2.  
    3. Turn the ignition OFF for 10 seconds.
    4.  
    5. Turn the ignition ON with the engine OFF.
    6.  
    7. Inspect for leaks.
    8.  

  48.  
  49. Install the engine sight shield.
  50.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.

  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Disconnect the following electrical connectors:

    EVAP purge solenoid
     
    Manifold absolute pressure (MAP) sensor
     
    Electronic throttle control (ETC)
     
    Oil pressure sensor
     
    Valve lifter oil manifold
     

  8.  
  9. Disconnect the generator electrical connector.
  10.  
  11. Remove the connector position assurance (CPA) retainer.
  12.  
  13. Disconnect the main ignition coil harness electrical connector.
    NOTE
    Mark the injector connectors to their corresponding injectors to ensure correct reassembly.

  14.  
  15. Disconnect the fuel injector electrical connectors.
  16.  
  17. Remove the CPA retainer.
  18.  
  19. Disconnect the main ignition coil harness electrical connector.
    NOTE
    Mark the injector connectors to their corresponding injectors to ensure correct reassembly.

  20.  
  21. Disconnect the fuel injector electrical connectors.
  22.  
  23. Remove the engine wiring harness retainers from the tabs on the fuel rail.
  24.  
  25. Reposition the harness out of the way.
  26.  
  27. Disconnect the fuel feed and EVAP lines.
  28.  
  29. Note the location of the fuel rail ground strap.
  30.  
  31. Remove the intake manifold bolt and ground strap.
  32.  
  33. Remove the fuel rail bolts.
  34.  
  35. Remove the fuel rail with injectors. Lift evenly on both sides of the fuel rail until all injectors have been removed from their bores.
    NOTE
    Do not separate the fuel injectors from the fuel rail unless component service is required.

  36.  
  37. Remove the fuel injector retaining clip, as required.
  38.  
  39. Remove the fuel injector, as required
  40.  
  41. Remove and discard the fuel injector O-ring seals, as required.

    Click image to see an enlarged view

    Fig. Fuel rail and injectors-5.3L engine

  42.  

To install


NOTE
Do not reuse the fuel injector O-ring seals. Install NEW O-ring seals during assembly.

  1. Note the installed location of the fuel rail ground strap.
  2.  
  3. Lubricate the NEW O-ring seals with clean engine oil.
  4.  
  5. Install the NEW fuel injector O-ring seals (532, 534) onto the injector, as required.
  6.  
  7. Install the fuel injector (533), as required
  8.  
  9. Install the fuel injector retaining clip (521), as required.
  10.  
  11. If necessary, lubricate the NEW O-ring seals with clean engine oil.
  12.  
  13. If necessary, install NEW O-ring seals to the fuel injectors.
  14.  
  15. Install the fuel rail (510) with injectors. Push firmly on both sides of the rail until all the injectors have been seated into their bores.
  16.  
  17. Apply a 0.2 in. (5mm) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the fuel rail bolts.
  18.  
  19. Install the fuel rail bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  20.  
  21. Install the ground strap and intake manifold bolt. Tighten the bolt to 89 inch lbs. (10 Nm).
  22.  
  23. Connect the fuel feed and EVAP lines.
  24.  
  25. Position the harness to the engine. Install the engine wiring harness retainers to the tabs on the fuel rail.
    NOTE
    Install the marked injector connectors to their corresponding injectors.

  26.  
  27. Connect the fuel injector electrical connectors.
  28.  
  29. Connect the main ignition coil harness electrical connector.
  30.  
  31. Install the CPA retainer.
    NOTE
    Install the marked injector connectors to their corresponding injectors.

  32.  
  33. Connect the fuel injector electrical connectors.
  34.  
  35. Connect the main ignition coil harness electrical connector.
  36.  
  37. Install the CPA retainer.
  38.  
  39. Connect the generator electrical connector.
  40.  
  41. Connect the following electrical connectors:

    EVAP purge solenoid
     
    MAP sensor
     
    ETC
     
    Oil pressure sensor
     
    Valve lifter oil manifold
     

  42.  
  43. Install the air cleaner outlet duct.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Use the following steps to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2.  
    3. Turn the ignition OFF for 10 seconds.
    4.  
    5. Turn the ignition ON with the engine OFF.
    6.  
    7. Inspect for leaks.
    8.  

  48.  
  49. Install the engine sight shield.
  50.  

 
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