GM Firebird 1982-1992 Repair Guide

Fuel Rail Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

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.

2.8L and 3.1L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the intake plenum.
  6.  
  7. Clean the fuel rail assembly to prevent dirt from entering the system.
  8.  
  9. Remove the cold start tube at the fuel rail fitting. Use a backup wrench on the fuel rail fitting to prevent it from turning.
  10.  
  11. Disconnect the fuel feed and return lines at the rail.
  12.  
  13. Disconnect the vacuum hose at the pressure regulator.
  14.  
  15. Unplug the electrical connectors.
  16.  
  17. Loosen and remove the fuel rail attaching bolts.
  18.  
  19. Remove the fuel rail assembly from the intake manifold.
  20.  
  21. Discard all of the O-ring seals that are exposed during this procedure.
  22.  

To install:
  1. Lubricate with clean engine oil, then install the injector nozzle O-rings.
  2.  
  3. Install the fuel rail assembly. Tilt the assembly to install the injectors.
  4.  
  5. Tighten the fuel rail attaching bolts to specification.
  6.  
  7. Engage the injector electrical connectors. Rotate each injector as required to avoid stretching the harness.
  8.  
  9. Connect the vacuum hose to the pressure regulator.
  10.  
  11. Connect the fuel feed and return lines. New O-rings must be used.
  12.  
  13. Install a new O-ring seal on the cold start tube. Thread the tube nut to the fitting on the fuel rail. Use a backup wrench on the fuel rail fitting to prevent it from turning.
  14.  
  15. Temporarily connect the negative battery terminal.
    1. With the engine OFF and the ignition ON, check for fuel leaks. Repair as necessary.
    2.  
    3. Disconnect the negative battery cable.
    4.  

  16.  
  17. Install the intake plenum using new gaskets.
  18.  
  19. Connect the negative battery cable.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: Fuel rail assembly on 2.8L engines



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Fig. Fig. 2: Fuel rail assembly on 3.1L engines



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Fig. Fig. 3: Fuel rail assembly on 3.8L engines

3.8L Turbo Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Label and disconnect all vacuum hoses and control cables which will interfere with fuel rail removal.
  6.  
  7. Remove the ignition coil, module and bracket.
  8.  
  9. Disengage the EGR valve cover.
  10.  
  11. Unplug the injector electrical connections.
  12.  
  13. Disconnect the vacuum hose at the pressure regulator.
  14.  
  15. Clean the fuel rail assembly to prevent dirt from entering the system.
  16.  
  17. Disconnect the fuel return and feed lines. Use a back-up wrench on the fuel rail fittings to prevent them from turning.
  18.  
  19. Remove the fuel rail attaching bolts, then remove the assembly from the engine.
  20.  
  21. Discard all of the O-ring seals that are exposed during this procedure.
  22.  

To install:
  1. Lubricate the new injector O-ring seals with clean engine oil, and install them on each injector.
  2.  
  3. Position the fuel rail on the intake manifold. Push down on the assembly to seat the injectors in the manifold.
  4.  
  5. Tighten the fuel rail attaching bolts to specification.
  6.  
  7. Using new O-rings, thread the fuel return and feed lines onto the fuel rail fittings. Use a back-up wrench to prevent them from turning.
  8.  
  9. Connect the vacuum hose to the pressure regulator and the injector wiring harness to the injectors.
  10.  
  11. Secure the EGR valve cover.
  12.  
  13. Install the ignition coil, module and bracket.
  14.  
  15. Connect all vacuum hoses and control cables removed earlier.
  16.  
  17. Connect the negative battery cable. With the engine OFF and the ignition ON, check for fuel leaks.
  18.  



Click image to see an enlarged view

Fig. Fig. 4: Fuel rail assembly on 5.0L and 5.7L engines

5.0L and 5.7L TPI Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the intake plenum and runners.
  6.  
  7. Clean the fuel rail assembly to prevent dirt from entering the system.
  8.  
  9. Disconnect the fuel feed and return lines at the rail. Use a back-up wrench to support the fuel rail tube fittings.
  10.  
  11. Disconnect the vacuum hose at the pressure regulator.
  12.  
  13. Unplug the electrical connectors.
  14.  
  15. Loosen and remove the fuel rail attaching bolts.
  16.  
  17. Remove the fuel rail assembly from the intake manifold.
  18.  
  19. Discard all of the O-ring seals that are exposed during this procedure.
  20.  

To install:
  1. Lubricate with clean engine oil, then install the injector nozzle O-rings.
  2.  
  3. Install the fuel rail assembly in the intake manifold.
  4.  
  5. Tighten the fuel rail attaching bolts to specification.
  6.  
  7. Engage the injector electrical connectors. Rotate each injector as required to avoid stretching the harness.
  8.  
  9. Connect the vacuum hose to the pressure regulator.
  10.  
  11. Connect the fuel feed and return lines. New O-rings must be used.
  12.  
  13. Temporarily connect the negative battery terminal.
    1. With the engine OFF and the ignition ON, check for fuel leaks. Repair as necessary.
    2.  
    3. Disconnect the negative battery cable.
    4.  

  14.  
  15. Install the intake plenum and runners. Use new gaskets.
  16.  
  17. Connect the negative battery cable.
  18.  

 
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