GM Camaro/Firebird 1993-1998 Repair Guide

Fuel Rail Assembly

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REMOVAL & INSTALLATION




WARNING
When servicing the fuel system, be sure to relieve the pressure of the system and drain the fuel into an approved container. Cap all open fuel lines and plug any other open passages. DO NOT allow dirt or other contaminants to enter the system.

3.4L Engines

See Figures 1, 2 and 3

This procedure requires the use of J-37088-A or an equivalent fuel line release tool set. These tools are necessary for disengaging the quick-connect fittings used on the fuel pipes.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Slide the rubber dust covers from the quick-connect fittings at the engine fuel pipes.
  6.  
  7. Grasp both sides of the fitting. Twist the female connector 1 / 4 turn in each direction to loosen any dirt within the fitting.
  8.  
  9. Using compressed air, blow the dirt out of the fitting.
  10.  


CAUTION
Safety goggles must be worn when using compressed air, as flying dirt particles may cause eye injury.

  1. Choose the correct size tool for the fitting. Insert the tool into the female connector, then push/pull inward to release the locking tabs.
  2.  
  3. Pull the connection apart.
  4.  

If it is necessary to remove rust or burrs from the fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to the O-ring sealing surface. Using a clean shop cloth, wipe the ends clean.

  1. Remove the engine fuel pipes.
  2.  
  3. Disconnect the vacuum hose at the pressure regulator.
  4.  
  5. Unplug the main electrical harness at the rail.
  6.  
  7. Loosen and remove the fuel rail attaching bolts.
  8.  
  9. Remove the fuel rail assembly from the intake manifold.
  10.  
  11. Discard all of the O-ring seals that are exposed during this procedure.
  12.  



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Fig. Fig. 1: Location of the fuel rail assembly identification number-3.4L engine



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Fig. Fig. 2: Exploded view of the fuel rail mounting-3.4L engine



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Fig. Fig. 3: Fuel rail assembly and related components-3.4L engine

To install:
  1. Lubricate with clean engine oil, then install the injector nozzle O-rings. Follow the procedures described earlier in this section under Fuel Injector removal.
  2.  
  3. Install the fuel rail assembly. Tilt the assembly to install the injectors.
  4.  
  5. Install and tighten the fuel rail attaching bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Connect the vacuum hose to the pressure regulator.
  8.  
  9. Install the fuel pipes. New O-rings must be used.
  10.  
  11. Apply a few drops of oil on the male end of the fuel pipes. Push both sides of the fitting together to cause the retaining tabs to snap into place.
  12.  
  13. Once installed, pull both sides of the fitting to make sure the connection is secure.
  14.  
  15. Slide the dust covers over the quick-connect fittings.
  16.  
  17. Engage the injector electrical connectors. Rotate each injector as required to avoid stretching the harness.
  18.  
  19. Connect the vacuum hose at the pressure regulator.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. With the engine off, turn the ignition switch to the ON position for 2 seconds, then turn it to the OFF position for 10 seconds. Again turn it to the ON position and check for fuel leaks.
  24.  

3.8L Engine

See Figure 4

This procedure requires the use of J-37088-A or an equivalent fuel line release tool set. These tools are necessary for disengaging the quick-connect fittings used on the fuel pipes.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Clean the fuel rail assembly and connections.
  6.  
  7. Remove the fuel feed and return pipes from the rail tubes by choosing the correct size tool for the fitting. Insert the tool into the female end of the connector, push inward and pull the connector apart.
  8.  
  9. Detach the fuel injector coil wires.
  10.  
  11. Disconnect the vacuum line from the vacuum source to the fuel pressure regulator.
  12.  
  13. Detach the MAP sensor electrical connector.
  14.  
  15. Remove the vacuum line to the vacuum switch from the fuel pipe bundle.
  16.  
  17. Detach the fuel injector electrical connectors.
  18.  
  19. Unfasten the fuel injector harness fasteners.
  20.  
  21. Remove the fuel rail hold-down bolts. Remove the fuel rail, using equal force to pull both sides of the rail up.
  22.  
  23. Remove the front fuel injector retaining clips on each side of the fuel rail.
  24.  
  25. Remove the front fuel injector on each side of the fuel rail. The fuel rail will now clear the intake manifold.
  26.  


WARNING
Do not damage the fuel injector connectors, tips or O-rings. Do NOT use compressed air to clean the fuel rail and NEVER submerge the fuel rail solvent to clean it.



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the fuel rail mounting-3.8L engine

To install:

Always install the 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. The O-rings are of the same size, but are made of different materials.

  1. Lightly lubricate the fuel injector O-rings with clean engine oil.
  2.  
  3. Place the fuel rail assembly, without the front injectors on each side the fuel rail, on the intake manifold.
  4.  
  5. Install the front fuel injector on each side of the fuel rail, then secure with the retaining clips. Seat the fuel injectors by hand.
  6.  
  7. Tighten the fuel rail hold-down bolts to 7 ft. lbs. (10 Nm).
  8.  
  9. Install the fuel injector harness fasteners. Attach the injector electrical connectors.
  10.  
  11. Fasten the vacuum source to the intake manifold.
  12.  
  13. Install the vacuum line to the vacuum switch from the fuel pipe bundle.
  14.  
  15. Connect the vacuum line from the vacuum source to the fuel pressure regulator.
  16.  
  17. Attach the fuel feed and return lines by pushing the pipes onto the fuel rail tubes.
  18.  
  19. Engage the MAP sensor electrical connector.
  20.  
  21. Attach the fuel injector coil wires.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. With the engine off, turn the ignition switch to the ON position for 2 seconds, then turn it to the OFF position for 10 seconds. Again turn it to the ON position and check for fuel leaks.
  26.  

5.7L Engine

See Figures 5, 6, 7, 8 and 9

This procedure requires the use of J-37088-A or an equivalent fuel line release tool set. These tools are necessary for disengaging the quick-connect fittings used on the fuel pipes.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the fuel rail cover.
  6.  



Click image to see an enlarged view

Fig. Fig. 5: Location of the fuel rail identification code

  1. Slide the rubber dust covers from the quick-connect fittings at the engine fuel pipes.
  2.  
  3. Grasp both sides of the fitting. Twist the female connector 1 / 4 turn in each direction to loosen any dirt within the fitting.
  4.  
  5. Using compressed air, blow the dirt out of the fitting.
  6.  


CAUTION
Safety goggles must be worn when using compressed air, as flying dirt particles may cause eye injury.

  1. Choose the correct tool from the J-37088-A tool set for the size of fitting. Insert the tool into the female connector, then push/pull inward to release the locking tabs.
  2.  
  3. Pull the connection apart.
  4.  

If it is necessary to remove rust or burrs from the fuel pipe, use emery cloth in a radial motion with the pipe end to prevent damage to the O-ring sealing surface. Using a clean shop cloth, wipe the ends clean.

  1. Disconnect the vacuum lines at the pressure regulator.
  2.  
  3. Tag and remove any vacuum lines necessary to gain access to the fuel rail and engine fuel pipes.
  4.  
  5. Disengage the electrical harness from the routing clips on the fuel rail.
  6.  
  7. Remove the engine fuel pipe retaining bolt.
  8.  
  9. Label then unplug the injector electrical connectors.
  10.  



Click image to see an enlarged view

Fig. Fig. 6: Label, then detach the fuel injector electrical connectors



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Fig. Fig. 7: Make sure to disconnect all vacuum lines and hoses in order to remove the fuel rail

  1. Remove the fuel rail attaching bolts, then separate the assembly from the manifold.
  2.  



Click image to see an enlarged view

Fig. Fig. 8: Unfasten the retaining bolts, then separate the fuel rail from the manifold



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Fig. Fig. 9: Exploded view of the fuel rail mounting-5.7L engine

To install:
  1. Discard all of the O-rings exposed during this procedure.
  2.  
  3. Lubricate the new lower (brown) O-rings with clean engine oil and install them on the injector nozzles. See the procedures described earlier in this section.
  4.  
  5. Install the fuel rail onto the manifold, then tighten the attaching bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Engage the injector electrical connections. Make sure each connector is installed on the proper injector to assure correct sequential injector firing order. Rotate the injectors as required to avoid stretching the harness.
  8.  
  9. Engage the engine wiring harness into the routing clips on the fuel rail.
  10.  
  11. Connect all vacuum lines to the intake manifold and the pressure regulator.
  12.  
  13. Apply a few drops of oil on the male end of the fuel pipes. Push both sides of the fitting together to cause the retaining tabs to snap into place.
  14.  
  15. Once installed, pull both sides of the fitting to make sure the connection is secure.
  16.  
  17. Slide the dust covers over the quick-connect fittings.
  18.  
  19. Install the fuel rail cover.
  20.  
  21. Tighten the fuel filler cap and connect the negative battery cable.
  22.  
  23. With the engine off, turn the ignition switch to the ON position for 2 seconds, then turn it to the OFF position for 10 seconds. Again turn it to the ON position and check for fuel leaks.
  24.  

 
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