GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Fuel Rail Assembly

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REMOVAL & INSTALLATION



1.8L And 2.0L OHC Engines

See Figure 1

  1. Properly relieve the fuel system pressure.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: The fuel rail is mounted on the intake manifold

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the throttle body from the intake manifold.
  4.  
  5. Disconnect the PCV and breather hoses from the camshaft cover.
  6.  
  7. Tag and detach the electrical connectors and vacuum hoses from the canister purge solenoid, EGR valve and solenoid and the MAP sensor.
  8.  
  9. Remove the MAP sensor from the bracket.
  10.  
  11. Detach the fuel injector electrical connectors.
  12.  
  13. Unfasten the fuel inlet pipe retainer attaching screw, then remove the retainer and the pump. Remove and discard the O-ring seal located under the seal retainer at the fuel rail.
  14.  
  15. Disconnect the fuel return pipe at the pressure regulator, using a back-up wrench to prevent it from turning.
  16.  
  17. Unfasten the fuel rail attaching bolts, then remove the fuel rail.
  18.  

If an injector becomes separated from the rail and remains in the cylinder head, both injector O-ring seals and the retainer clip must be replaced.

To install:
  1. Position the fuel rail assembly, then install the retaining bolts. Tighten the bolts to 19 ft. lbs. (26 Nm).
  2.  
  3. Install a new fuel inlet pipe O-ring seal, coated with clean engine oil, under the seal retainer at the fuel rail. Tighten the retaining screw to 53 inch lbs. (6 Nm).
  4.  
  5. Connect the fuel return pipe. Tighten the fuel return pipe fitting to 14.8 ft. lbs. (20 Nm). Make sure to use a back-up wrench on the pressure regulator fitting to prevent it from turning.
  6.  
  7. Attach the injector electrical connectors.
  8.  
  9. Fasten the MAP sensor to the bracket. Tighten the screws to 27 inch lbs. (3 Nm).
  10.  
  11. Install the canister purge solenoid and bracket and the EGR solenoid and bracket. Tighten the bracket retaining screws to 37 ft. lbs. (50 Nm).
  12.  
  13. Connect the canister purge solenoid and the EGR solenoid and valve vacuum hoses and electrical connectors.
  14.  
  15. Fasten the PCV and breather hoses to the camshaft cover.
  16.  
  17. Install the throttle body, as outlined earlier in this section.
  18.  
  19. Tighten the fuel filler cap.
  20.  
  21. Connect the negative battery cable, then with the engine OFF , check to see that the accelerator pedal is free by depressing, then releasing it. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Again turn the switch to the ON position and check for fuel leaks.
  22.  

2.8L and 3.1L Engines
1985-86 VEHICLES

See Figure 2

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the fuel rail assembly - 1985-86 2.8L engines

  1. Relieve fuel system pressure.
  2.  
  3. Remove the intake manifold plenum, as follows:
    1. Disconnect the vacuum lines.
    2.  
    3. Remove the EGR-to-plenum nuts.
    4.  
    5. Unfasten the two throttle body bolts.
    6.  
    7. Remove the throttle cable to bracket bolts.
    8.  
    9. Unfasten the plenum bolts and remove the plenum and gasket.
    10.  

  4.  
  5. Remove the cold start valve and tube assembly.
  6.  
  7. Remove the retaining nut from the stud for the fuel lines at the head.
  8.  
  9. Unfasten the fuel lines at the rail.
  10.  
  11. Disconnect the vacuum line at the regulator.
  12.  
  13. Remove the rail retaining bolts.
  14.  
  15. Disconnect the injector electrical connectors.
  16.  
  17. Remove the fuel rail assembly.
  18.  

To install:
  1. Use new injector O-rings which have been lubricated with engine clean oil.
  2.  
  3. The remainder of installation is the reverse of the removal procedure.
  4.  
  5. Connect the negative battery cable. 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.
  6.  

1987-94 VEHICLES

See Figure 3

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the intake manifold plenum and fuel rail - 1987-94 2.8L and 3.1L engines

  1. Properly relieve fuel system pressure.
  2.  
  3. Remove the intake manifold plenum, as follows:
    1. Disconnect the vacuum lines.
    2.  
    3. Remove the EGR-to-plenum nuts.
    4.  
    5. Unfasten the two throttle body bolts.
    6.  
    7. Remove the throttle cable to bracket bolts.
    8.  
    9. Unfasten the ignition wire plastic shield bolts.
    10.  
    11. Remove the plenum bolts and remove the plenum and gasket.
    12.  

  4.  
  5. Remove the fuel line bracket bolt.
  6.  
  7. Disconnect the fuel lines at the rail.
  8.  


CAUTION
Wrap a cloth around the fuel lines to collect fuel, then place the fuel in an approved container.

  1. Remove the fuel line O-rings.
  2.  
  3. Disconnect the vacuum line at the pressure regulator.
  4.  
  5. Unfasten the four rail retaining bolts.
  6.  
  7. Detach the injector electrical connectors.
  8.  
  9. Remove the fuel rail assembly.
  10.  
  11. Remove the O-ring seal from each of the spray tip end of the injector.
  12.  

To install:
  1. Lubricate new the O-ring seals, with clean engine oil and install to each of the spray tip ends of the injector.
  2.  
  3. Position the fuel rail assembly in the intake manifold and tilt the rail assembly and install the injectors.
  4.  
  5. Install the fuel rail attaching bolts and tighten to 19 ft. lbs. (26 Nm).
  6.  
  7. Attach the injector electrical connectors.
  8.  
  9. Connect the vacuum line at the pressure regulator.
  10.  
  11. Install new O-rings on the inlet and return fuel lines.
  12.  
  13. Tighten the fuel filler cap.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Using a back-up wrench, install the fuel inlet and outlet fittings.
  18.  
  19. Connect the negative battery cable. 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.
  20.  
  21. Reversing the removal procedure, install the intake manifold plenum.
  22.  

This test must be done before the engine is started and requires the use of a Tech 1® scan tool.

  1. If equipped with the 3.1L engine, perform the idle learn procedure to allow the ECM/PCM memory to be updated with the correct IAC valve pintle position and provide for a stable idle speed.
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  

 
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