GM Corsica/Beretta 1988-1996 Repair Guide

Fuel Rail Assembly

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REMOVAL & INSTALLATION



2.3L Engines

See Figures 1, 2, 3, 4 and 5

  1. Properly relieve the fuel system pressure.
  2.  
  3. If not done already, disconnect the negative battery cable.
  4.  
  5. Disconnect the hoses from the front and side of the crankcase ventilation oil/air separator. Leave the vacuum hose attached to the canister purge solenoid.
  6.  
  7. Remove the bolts attaching the crankcase ventilation oil/air separator and canister purge solenoid.
  8.  
  9. Disconnect the hose from the bottom of the separator, then remove the separator. Position the canister purge solenoid out of the way.
  10.  
  11. Remove the fuel pipe clamp bolt.
  12.  
  13. Disconnect the vacuum hose at the pressure regulator.
  14.  
  15. Remove the fuel rail attaching bolts, then remove the fuel rail from the cylinder head.
  16.  
  17. Remove the injector electrical connectors by pushing in the wire connector clip, while pulling the connector away from the injector.
  18.  
  19. Disconnect the fuel inlet pipe at the fuel rail. Use a back-up wrench on the fuel rail inlet fitting to prevent it from turning.
  20.  
  21. Loosen the fuel return pipe retaining bracket attaching screw and rotate the retaining bracket to allow the fuel pipe to be removed.
  22.  
  23. Disconnect the fuel return pipe from the pressure regulator.
  24.  
  25. Remove the fuel rail assembly.
  26.  
  27. If necessary, unfasten the quick connect fittings at fuel pipes from the fuel feed and return lines as follows:
    1. Grasp both ends of the fuel line connection and twist the quick connect fitting 1 / 4 turn in each direction to loosen any dirt within the fitting. Repeat for the other nylon fuel connecting line fitting.
    2.  
    3. Select the correct tool from J 37088 tool set or its equivalent, and insert the tool into the female connector, then push inward to release the male connector.
    4.  
    5. Repeat for the other fitting.
    6.  

  28.  
  29. Disassemble as follows:
    1. Remove the injector O-ring seal from the spray tip of each injector and discard.
    2.  

  30.  

If an injector was separated from the rail during removal, remove both injector O-rings.

  1. Remove the injector clips, if necessary.
  2.  
  3. If the fuel pipes were disconnect from the fuel rail, remove the fuel inlet and return tube O-ring seals and tube seals and discard.
  4.  



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Fig. Fig. 1: Exploded view of the fuel rail and front fuel pipe mounting - 1990 2.3L engine



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Fig. Fig. 2: Fuel rail and front fuel pipe removal and installation - 1991-94 2.3L engines



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Fig. Fig. 3: Exploded view of the fuel rail and related components - 1990 2.3L engine



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Fig. Fig. 4: Exploded view of the fuel rail and related components - 1991 2.3L engine



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Fig. Fig. 5: Fuel rail, injectors, pressure regulator and other system components - 1992-94 2.3L engines

To install
  1. Assemble as follows:
    1. Lubricate new injector O-ring seals with clean engine oil, and install on the injectors.
    2.  
    3. Install new injector retaining clips, if necessary.
    4.  
    5. If separated from the fuel rail, install the injector(s) into the fuel rail injector sockets, with the electrical connector facing outward. Push in far enough to engage the retainer clip over the fuel rail extrusion flange.
    6.  
    7. If the fuel pipes were disconnected from the fuel rail, install new inlet and return tube O-ring seals and retainers. Press the retainer in to contact the O-ring. Lubricate the seals with clean engine oil.
    8.  

  2.  
  3. If the fuel rail was disconnected from the fuel pipes, apply a few drops of clean engine oil to the male end of the fuel pipes and reconnect the fuel pipes to the rail at this time.
  4.  
  5. Attach the return pipe to the regulator, aligning the bracket. Apply Loctite® 262, or equivalent, to the threads of the fuel return pipe bracket screw and tighten to 53 inch lbs. (6 Nm).
  6.  
  7. Using a back-up wrench, install the fuel inlet nut to 22 ft. lbs. (30 Nm).
  8.  
  9. Position the fuel rail over the cylinder head, and connect the injector electrical connectors. Rotate the injector(s) as required to avoid stretching the wire harness.
  10.  
  11. Install the fuel rail assembly to the cylinder head and tighten the attaching bolts to 19 ft. lbs. (26 Nm).
  12.  
  13. Install the vacuum hose to the pressure regulator.
  14.  
  15. If the fuel pipes were disconnected at the fuel feed and return line quick-connect fittings, reconnect them as follows:
    1. Apply a few drops of clean engine oil to the male tube ends of the engine fuel feed and return pipes.
    2.  
    3. Push the connectors together to cause the retaining the retaining tabs/fingers to snap into place. Pull on both ends of each connection to make sure they are secure. Repeat for the other fitting.
    4.  

  16.  


CAUTION
During normal operation, O-rings, located in the female connector will swell and may prevent proper reconnection if not lubricated. This will prevent a possible fuel leak.

  1. Install the fuel pipe clamp bolt and tighten to 106 inch lbs. (12 Nm).
  2.  
  3. Connect the hose to the bottom of the crankcase ventilation oil/air separator.
  4.  
  5. Position the separator and canister purge solenoid over the attaching bosses.
  6.  
  7. Install the separator and solenoid attaching bolts and tighten to 71 inch lbs. (8 Nm).
  8.  
  9. Connect the hoses to the front and the sides of the separator.
  10.  
  11. Tighten the fuel filler cap and connect the negative battery cable.
  12.  

2.8L and 3.1L Engines
1988-95 VEHICLES

See Figures 6, 7, 8 and 9


CAUTION
To reduce the risk of fire or personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system.

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

      Click image to see an enlarged view

      Fig. Fig. 6: Exploded view of the upper intake manifold, gaskets and fuel rail - 1988-93 vehicles



      Click image to see an enlarged view

      Fig. Fig. 7: Exploded view of the intake plenum and related components - 1994-95 vehicles

    12.  

  6.  
  7. Remove the fuel line bracket bolt.
  8.  
  9. Use a back-up wrench to disconnect the fuel lines from the rail.
  10.  


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

  1. Remove and discard the fuel inlet and return line O-rings.
  2.  
  3. Disconnect the vacuum line from the pressure regulator.
  4.  
  5. Remove the rail retaining bolts.
  6.  
  7. Detach the injector electrical connectors.
  8.  
  9. Remove the fuel rail assembly from the vehicle.
  10.  
  11. If necessary, disassemble by removing the O-ring seal from each of the spray tip end of the injector.
  12.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of the fuel rail and related components - 1988-93 vehicles



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Fig. Fig. 9: Exploded view of the fuel rail and related components - 1994-95 vehicles

To install:
  1. Lubricate new O-ring seals with clean engine oil, then install on each of the spray tip ends of the injector.
  2.  
  3. Install the fuel rail assembly to the intake manifold. Tilt the fuel rail assembly to install the injectors.
  4.  
  5. Install the fuel rail attaching bolts and tighten to 19 ft. lbs. (25 Nm) for 1988 vehicles, and to 88 inch lbs. (10 Nm) for 1989-95 vehicles.
  6.  
  7. Attach the injector electrical connectors.
  8.  
  9. Connect the vacuum line to the pressure regulator.
  10.  
  11. Install new O-rings on the inlet and return fuel lines, then connect the fuel inlet and outlet fittings, using a back-up wrench to tighten the lines. Tighten the fuel pipe nuts to 22 ft. lbs. (30 Nm).
  12.  
  13. Connect the negative battery cable. Tighten the fuel filler cap.
  14.  
  15. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Turn the ignition switch to the ON position again and check for leaks.
  16.  
  17. Install the intake manifold plenum.
  18.  

1996 VEHICLES

See Figures 10, 11, 12, 13 and 14

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the upper intake manifold.
  6.  
  7. Disconnect the engine fuel feed pipe from the fuel rail, using a back-up wrench.
  8.  
  9. Remove the fuel pressure regulator from the fuel rail.
  10.  
  11. Remove and discard the fuel inlet pipe and pressure regulator O-rings.
  12.  
  13. Detach the main injector harness electrical connector.
  14.  



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Fig. Fig. 10: Unplug the main injector harness electrical connector



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Fig. Fig. 11: Some connectors have a Connector Position Assurance (CPA) retaining clip (see arrow)

  1. Unplug the coolant temperature sensor electrical connector.
  2.  
  3. Unfasten the fuel rail retaining bolts, then remove the fuel rail assembly from the vehicle.
  4.  



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Fig. Fig. 12: Remove the fuel rail-to-manifold retaining bolts ...



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Fig. Fig. 13: ... then remove the fuel rail assembly from the intake manifold

  1. Remove and discard the injector O-ring seal from the spray tip end of each injector. With the O-ring removed, the O-ring back-up may slip off the injector. Be sure to retain the O-ring back-up for reuse.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Exploded view of the fuel rail mounting - 1996 3.1L engines

To install:

Be careful not to damage the fuel injector electrical connector, the injector tips, O-rings and inlet and outlet of the fuel rail.


WARNING
Never use compressed air or immerse the fuel rail as a method of cleaning the rail assembly.

  1. Make sure the O-ring back-ups are on the injector before installing new O-rings. Lubricate new injector O-ring seals with clean engine oil and install on the spray tip end of each injector.
  2.  
  3. Install the fuel rail in the intake manifold. Install the rail attaching bolts and tighten to 7 ft. lbs. (10 Nm).
  4.  
  5. Attach the coolant temperature sensor electrical connector.
  6.  
  7. Connect the main injector wiring harness.
  8.  
  9. Install new O-rings on the fuel rail inlet line and fuel pressure regulator.
  10.  
  11. Install the fuel feed and tighten the pipe nut to 13 ft. lbs. (17 Nm), using a back-up wrench.
  12.  
  13. Install the fuel pressure regulator.
  14.  
  15. Install the upper intake manifold.
  16.  
  17. Install the fuel filler cap.
  18.  
  19. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Turn the ignition switch to the ON position again and check for leaks.
  20.  

 
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