GM Cavalier/Sunfire 1995-2000 Repair Guide

Fuel Rail Assembly

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REMOVAL & INSTALLATION



2.3L Engine

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the fuel rail and related components-2.3L and 2.4L engines

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the hoses at the front and side of the crankcase ventilation oil/air separator. Leave the vacuum hoses attached to the canister purge valve.
  6.  
  7. Unfasten the bolts securing the crankcase ventilation oil/air separator and canister purge valve.
  8.  
  9. Disconnect the hose from the bottom of the separator, then remove the separator. Position the canister purge valve out of the way.
  10.  
  11. Remove the fuel pipe clamp bolt.
  12.  
  13. Disconnect the vacuum hose at the pressure regulator.
  14.  
  15. Unfasten the fuel rail attaching bolts, then remove the fuel rail assembly from the cylinder head.
  16.  
  17. Detach the fuel injector electrical connectors. Push in the wire connector clip, while pulling the connector away from the injector.
  18.  
  19. Remove the fuel rail assembly, making sure to cover all openings with masking tape to prevent dirt entry. Remove discard all O-rings and seals and replace with new ones during installation.
  20.  

If any injectors become separated from the fuel rail and remain in the intake manifold, both O-ring seals and injector retaining clip must be replaced. Use care in removing the fuel rail assembly, to prevent damage to the injector electrical connector terminals and the injector spray tips. When removed, support the fuel rail to avoid damaging its components. The fuel injector is serviced as a complete unit only. Since it is an electrical component, it should not be immersed in any type of cleaner.

To install:
  1. Be sure to lubricate all the new O-rings and seals with clean engine oil. Carefully push the injectors into the cylinder head intake ports until the bolt holes on the fuel rail and manifold are aligned.
  2.  
  3. The remainder of the installation is the reverse order of the removal procedure.
  4.  
  5. Apply a coating of a suitable thread locking compound on the treads of the fittings. Tighten the fuel rail retaining bolts to 19 ft. lbs. (26 Nm), the fuel feed line nut to 22 ft. lbs. (30 Nm) and the fuel pipe fittings to 20 ft. lbs. (26 Nm).
  6.  
  7. 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.
  8.  

2.4L Engine

See Figure 1

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner outlet resonator.
  6.  
  7. Remove the fuel pressure regulator vacuum hose.
  8.  
  9. Remove the fuel rail attaching bolts.
  10.  
  11. Detach the Camshaft Position (CMP) sensor connector.
  12.  
  13. Detach the fuel injector connectors.
  14.  
  15. Remove the fuel feed line retaining bolt and remove the line from the fuel rail.
  16.  
  17. Lift the fuel rail from the cylinder head.
  18.  
  19. Loosen the fuel return line retaining bracket attaching screw. Rotate the retaining bracket so that the return line can be removed.
  20.  
  21. Remove the return line from the pressure regulator.
  22.  
  23. Detach the fuel feed and fuel return line quick-connect fittings and remove the fuel lines from the vehicle.
  24.  
  25. Remove the fuel rail assembly from the vehicle.
  26.  

To install:
  1. With the fuel rail outside the vehicle, attach the fuel feed and return lines to the rail.
  2.  
  3. Tighten the feed line retaining bolt to 22 ft. lbs. (30 Nm). Tighten the return line bracket bolts to 53 inch lbs. (6 Nm).
  4.  
  5. Place the fuel rail over the cylinder head and attach the fuel injector connectors. Rotate the fuel injectors if necessary to avoid stretching the wire harness.
  6.  
  7. Replace the O-rings on the injectors and lubricate them with clean engine oil before installation.
  8.  
  9. Install the fuel rail into the cylinder head. Ensure that the O-rings are in place and the fuel rail is fully seated.
  10.  
  11. Attach the Camshaft Position (CMP) sensor connector.
  12.  
  13. Tighten the fuel rail attaching bolts to 19 ft. lbs. (26 Nm).
  14.  
  15. Attach the fuel pressure regulator vacuum hose.
  16.  
  17. Attach the fuel feed and return line quick connect fittings.
  18.  
  19. Install the air cleaner outlet resonator.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the vehicle and check for leaks.
  24.  

1998-00 2.2L Engine

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Remove the fuel rail bracket from the engine to access the fuel rail

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner outlet resonator.
  6.  
  7. Remove the fuel rail bracket.
  8.  
  9. Detach the fuel injector connectors.
  10.  
  11. Detach the fuel feed and fuel return line quick-connect fittings.
  12.  
  13. Remove the fuel rail attaching bolts.
  14.  
  15. Remove the fuel rail from the cylinder head.
  16.  

To install:
  1. Install the fuel rail into the cylinder head. Ensure that the O-rings are in place and the fuel rail is fully seated.
  2.  
  3. Tighten the fuel rail attaching bolts to 18 ft. lbs. (24 Nm).
  4.  
  5. Attach the fuel feed and return line quick connect fittings.
  6.  
  7. Attach the fuel injector connectors.
  8.  
  9. Install the fuel rail bracket bolts and nuts and tighten to:

    Tighten the front nuts to 89 inch lbs. (10 Nm).
     
    Tighten the remaining bolts and nuts to 18 ft. lbs. (25 Nm).
     

  10.  
  11. Install the air cleaner outlet resonator.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the vehicle and check for leaks.
  16.  

 
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