GM Century/Lumina/Grand Prix/Intrigue 1997-2000

Fuel Rail Assembly

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The fuel rail assembly has two sides, to deliver fuel to the injectors on each bank of cylinders. The fuel rail assembly includes the fuel injectors, which are retained by clips to the fuel rail, the fuel pressure regulator and connections for the fuel feed pipe and the fuel return pipe. The fuel rail assembly is installed to the lower half of the intake manifold and the rail must be removed to service the fuel injectors.


CAUTION
When servicing any fuel rail component, precautions must be taken to prevent dirt and other contaminates from entering the fuel passages. It is recommended that the fittings be capped and the holes plugged during servicing.

REMOVAL & INSTALLATION



3.1L and 3.4L (VIN E) Engines

If replacing a damaged fuel rail, look for an eight digit identification number stamped on the left side fuel rail. Refer to this number if servicing or part replacement is required.

  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure using the procedures found in this section.
  4.  
  5. Remove the upper intake manifold, as outlined in of this guide.
  6.  
  7. Disconnect the engine fuel feed pipe at the fuel rail.
  8.  
  9. Remove the fuel pressure regulator from the fuel rail using the procedures found in this section.
  10.  
  11. Remove the fuel inlet pipe and fuel pressure regulator O-rings and discard.
  12.  
  13. Detach the main injector harness electrical connector.
  14.  
  15. Unplug the ECT sensor harness connector.
  16.  
  17. Remove the fuel rail retaining bolts and gently lift up on the rail assembly to loosen the injector O-rings from the lower intake manifold.
  18.  
  19. Remove and discard the lower O-ring from each injector, taking care to retain the nylon O-ring back-up piece.
  20.  



Click image to see an enlarged view

Fig. Fuel rail arrangement-3.1L & 3.4L (VIN E) engines

To install:

  1. Clean all parts well. Care must be taken not to damage or dirty the fuel injector electrical connectors, the fuel injector tips, the O-rings and the inlet and the outlet of the fuel rail. Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components. The fuel rail must not be immersed in solvent to avoid damage to the fuel rail assembly. Make sure that O-ring back-ups are on the injectors before installing the new O-rings on the injectors. Lubricate the new O-rings with clean engine oil and install on the spray tip end of each injector.
  2.  
  3. Install the fuel rail and injector assembly to the lower intake manifold. Tilt the rail assembly as required to get all of the injectors properly installed. Install the rail attaching bolts and tighten to 84 inch lbs. (10 Nm).
  4.  
  5. Attach the main injector harness connector, as well as the ECT sensor connector.
  6.  
  7. Install new O-rings on the fuel rail inlet line and fuel pressure regulator. Install the fuel feed pipe and tighten the nut to 13 ft. lbs. (17 Nm).
  8.  
  9. Install the fuel pressure regulator using the procedures found in this section.
  10.  
  11. Install the upper intake manifold. Please see .
  12.  
  13. Connect the negative battery cable.
  14.  

3.4L (VIN X) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure using the procedures found in this section.
  4.  
  5. Remove the upper intake manifold, as outlined in of this guide.
  6.  
  7. Disconnect the engine fuel feed and return pipes from the fuel rail tubes by squeezing the tabs and pulling the lines apart.
  8.  
  9. Disconnect the fuel pressure regulator vacuum line.
  10.  
  11. Detach the main injector harness electrical connector.
  12.  
  13. Remove the fuel rail retaining bolts and gently lift up on the rail assembly to loosen the injector O-rings from the lower intake manifold.
  14.  
  15. Remove and discard the lower O-ring from each injector, taking care to retain the nylon O-ring back-up piece.
  16.  



Click image to see an enlarged view

Fig. Fuel rail arrangement-3.4L (VIN X) engine

To install:

  1. Clean all parts well. Care must be taken not to damage or dirty the fuel injector electrical connectors, the fuel injector tips, the O-rings and the inlet and the outlet of the fuel rail. Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components. The fuel rail must not be immersed in solvent to avoid damage to the fuel rail assembly. Make sure that O-ring back-ups are on the injectors before installing the new O-rings on the injectors. Lubricate the new O-rings with clean engine oil and install on the spray tip end of each injector.
  2.  
  3. Install the fuel rail and injector assembly to the lower intake manifold. Tilt the rail assembly as required to get all of the injectors properly installed. Install the rail attaching bolts and tighten to 84 inch lbs. (10 Nm).
  4.  
  5. Attach the main injector harness connector and connect the pressure regulator vacuum line.
  6.  
  7. Connect the fuel feed and return lines.
  8.  
  9. Install the upper intake manifold. Please see .
  10.  
  11. Connect the negative battery cable.
  12.  

3.5L (VIN H) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure using the procedures found in this section.
  4.  
  5. Clean the fuel rail assembly and connections.
  6.  
  7. Disconnect the engine fuel feed pipe quick connect fitting from the fuel rail tubes by squeezing the tabs and pulling the lines apart.
  8.  
  9. Disconnect the return fuel pipe quick connect fitting from the fuel rail.
  10.  
  11. Disconnect the vacuum lines to the fuel pressure regulator, the PCV valve and the throttle body.
  12.  
  13. Remove the snap bracket on the throttle body coolant hose.
  14.  
  15. Remove the engine electrical harness bolts on the camshaft covers.
  16.  
  17. Tag for identification, then detach the injector harness electrical connectors.
  18.  
  19. Release the four snap locking tabs on the fuel rail assembly by pushing toward the camshaft covers and lifting.
  20.  
  21. Remove the fuel rail by gently lifting up to loosen the injector O-rings from the lower intake manifold. Work with equal force on both sides of the fuel rail to avoid bending the fuel rail.
  22.  



Click image to see an enlarged view

Fig. View of the fuel rail assembly-3.5L (VIN H) engine

To install:

  1. Clean all parts well. Care must be taken not to damage or dirty the fuel injector electrical connectors, the fuel injector tips, the O-rings and the inlet and the outlet of the fuel rail. Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components. The fuel rail must not be immersed in solvent to avoid damage to the fuel rail assembly. Make sure that O-ring back-ups are on the injectors before installing the new O-rings on the injectors. Lubricate the new O-rings with clean engine oil and install on the spray tip end of each injector.
  2.  
  3. Install the fuel rail and injector assembly onto the lower intake manifold. A snap will be heard when the injectors are properly seated.
  4.  
  5. Using the identification tags made at removal, attach the electrical connectors to the fuel injectors. Install the harness bolts on the camshaft covers. Tighten to 80 inch lbs. (9 Nm).
  6.  
  7. Install the snap bracket on the throttle body coolant tube.
  8.  
  9. Connect the vacuum hoses to the throttle body, the PCV valve and the fuel pressure regulator.
  10.  
  11. Connect the fuel return pipe and fuel feed pipe to their quick-connect fittings using the procedures found in this section.
  12.  
  13. Connect the negative battery cable.
  14.  

3.8L (VIN K) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure using the procedures found in this section.
  4.  
  5. Clean the fuel rail assembly and connections.
  6.  
  7. Disconnect the engine fuel feed and return pipes from the fuel rail tubes by squeezing the tabs and pulling the lines apart.
  8.  
  9. Disconnect the vacuum lines to the fuel pressure regulator and the throttle body.
  10.  
  11. Detach the ignition coil wires.
  12.  
  13. Tag for identification, then detach the injector harness electrical connectors.
  14.  
  15. Remove the fuel rail retaining bolts and gently lift up on the rail assembly to loosen the injector O-rings from the lower intake manifold. Work with equal force on both sides of the fuel rail to avoid bending the fuel rail.
  16.  
  17. Remove and discard the lower O-ring from each injector, taking care to retain the nylon O-ring back-up piece.
  18.  



Click image to see an enlarged view

Fig. View of the fuel rail assembly-3.8L (VIN K) engine

To install:

  1. Clean all parts well. Care must be taken not to damage or dirty the fuel injector electrical connectors, the fuel injector tips, the O-rings and the inlet and the outlet of the fuel rail. Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components. The fuel rail must not be immersed in solvent to avoid damage to the fuel rail assembly. Make sure that O-ring back-ups are on the injectors before installing the new O-rings on the injectors. Lubricate the new O-rings with clean engine oil and install on the spray tip end of each injector.
  2.  
  3. Install the fuel rail and injector assembly to the lower intake manifold. Seat the fuel injectors by hand. Install the rail attaching bolts and tighten to 84 inch lbs. (10 Nm).
  4.  
  5. Using the identification tags made at removal, attach the electrical connectors to the fuel injectors.
  6.  
  7. Connect the fuel feed and return lines to the fuel rail.
  8.  
  9. Connect the vacuum lines to the pressure regulator vacuum line and the throttle body.
  10.  
  11. Install the ignition coil wires.
  12.  
  13. Connect the negative battery cable.
  14.  

3.8L (VIN 1) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure using the procedures found in this section.
  4.  
  5. Clean the fuel rail assembly and connections.
  6.  
  7. Disconnect the engine fuel feed and return pipes from the fuel rail tubes by squeezing the tabs and pulling the lines apart.
  8.  
  9. Detach the vacuum lines from the fuel pressure regulator and the throttle body.
  10.  
  11. Disconnect the ignition coil wires from the coil and retainer clips on top of the supercharger.
  12.  
  13. Remove the alternator and rear bracket. Please see .
  14.  
  15. Remove the supercharger bypass valve actuator.
  16.  
  17. Tag for identification, then detach the injector harness electrical connectors. Remove the fuel injector electrical harness clips holding the harness to the front of the fuel rail.
  18.  
  19. Remove the fuel rail retaining fasteners (4 bolts, 1 stud) and gently lift up on the rail assembly to loosen the injector O-rings from the lower intake manifold. Work with equal force on both sides of the fuel rail to avoid bending the fuel rail.
  20.  
  21. Remove and discard the lower O-ring from each injector, taking care to retain the nylon O-ring back-up piece.
  22.  



Click image to see an enlarged view

Fig. Fuel rail arrangement-3.8L (VIN 1) engine

To install:

  1. Clean all parts well. Care must be taken not to damage or dirty the fuel injector electrical connectors, the fuel injector tips, the O-rings and the inlet and the outlet of the fuel rail. Compressed air must not be used to clean the fuel rail assembly, as this may damage the fuel rail components. The fuel rail must not be immersed in solvent to avoid damage to the fuel rail assembly. Make sure that O-ring back-ups are on the injectors before installing the new O-rings on the injectors. Lubricate the new O-rings with clean engine oil and install on the spray tip end of each injector.
  2.  
  3. Install the fuel rail and injector assembly to the lower intake manifold. Seat the fuel injectors by hand. Install the rail attaching bolts and tighten to 84 inch lbs. (10 Nm). Tighten the stud to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the supercharger bypass valve actuator.
  6.  
  7. Install the alternator and rear bracket. Please see .
  8.  
  9. Using the identification tags made at removal, attach the electrical connectors to the fuel injectors. Install the harness clips to the font of the fuel rail.
  10.  
  11. Install the ignition coil wires to the coil and to the retainer clips on top of the supercharger.
  12.  
  13. Connect the fuel feed and return lines to the fuel rail.
  14.  
  15. Connect the vacuum lines to the pressure regulator vacuum line and the throttle body.
  16.  
  17. Connect the negative battery cable.
  18.  

 
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