GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Fuel Rail Assembly

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When servicing the fuel rail assembly, be careful to prevent dirt and other contaminants from entering the fuel passages. Fittings should be capped and holes plugged during servicing. At any time the fuel system is opened for service, the O-ring seals and retainers used with related components should be replaced.

Before removing the fuel rail, the fuel rail assembly may be cleaned with a spray type cleaner, GM-30A or equivalent, following package instructions. Do not immerse fuel rails in liquid cleaning solvent. Be sure to always use new O-rings and seals when reinstalling the fuel rail assemblies.

There is an 8-digit number stamped on the under side of the fuel rail assembly on 4 cylinder engines and on the left hand fuel rail on dual rail assemblies (fueling even cylinders No. 2, 4, 6). Refer to this number if servicing or part replacement is required.

REMOVAL & INSTALLATION2.0L Engine



See Figure 1

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Fig. Fig. 1: Fuel rail and pressure regulator removal-2.0L engine

  1. Properly relieve fuel system pressure.
  2.  
  3. If not done already, disconnect the negative battery cable.
  4.  
  5. Remove the air intake ducts and/or passages in order to gain access to the fuel rail.
  6.  
  7. Disconnect and plug the fuel line from the fuel rail.
  8.  
  9. Carefully detach the fuel injector electrical connectors, then lay the harness aside.
  10.  
  11. Remove the pressure regulator assembly, as required to ease removal of the fuel rail.
  12.  
  13. Unfasten the fuel rail mounting hardware.
  14.  
  15. Carefully remove the fuel injectors from the intake manifold.
  16.  
  17. Remove the fuel rail from the vehicle.
  18.  
  19. Remove and discard the fuel injector O-rings.
  20.  

To install:
  1. Lubricate new O-rings with a light coating of clean engine oil. Install the O-rings.
  2.  
  3. Carefully install the fuel injectors to the intake manifold.
  4.  
  5. Install the fuel rail attaching hardware.
  6.  
  7. If removed, install the pressure regulator.
  8.  
  9. Attach the fuel injector electrical connectors.
  10.  
  11. Connect the fuel line to the fuel rail.
  12.  
  13. Install the air intake ducts and/or passages.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Turn the ignition key to the ON position. Check for fuel leaks.
  18.  
  19. Start the engine and allow to idle. Recheck for leaks.
  20.  

2.3L Engine See Figure 2

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Fig. Fig. 2: Exploded view of the fuel rail and related components-2.3L engine

  1. Properly relieve the fuel system pressure. If not done already, disconnect the negative battery cable.
  2.  
  3. Disconnect the hoses at the front and side of the crankcase ventilation oil/air separator. Leave the vacuum hoses connected to the EVAP canister purge control solenoid.
  4.  
  5. Unfasten the bolts attaching the oil/air separator and the EVAP solenoid valve.
  6.  
  7. Disconnect the hose to the bottom of the separator, then remove the crankcase ventilation oil/air separator. Position the canister purge solenoid valve out of the way.
  8.  
  9. Disconnect the fuel feed line and return line from the fuel rail assembly, be sure to use a backup wrench on the inlet fitting to prevent turning.
  10.  
  11. Remove the vacuum line at the pressure regulator.
  12.  
  13. Unfasten the fuel rail assembly retaining bolts.
  14.  
  15. Detach the injector electrical connectors by pushing in the wire connector clip, while pulling the connector away from the injector.
  16.  
  17. 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.
  18.  

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 3

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Fig. Fig. 3: Exploded view of the fuel rail and pressure regulator assembly-2.4L engine

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Loosen the air cleaner outlet duct clamp.
  6.  
  7. Remove the air cleaner outlet duct from the air cleaner resonator.
  8.  
  9. Loosen the air cleaner resonator clamp at the throttle body.
  10.  
  11. Remove the bolts securing the resonator.
  12.  
  13. Remove the resonator from the throttle body.
  14.  
  15. Remove the crankcase vent hose to bottom of the resonator, then extract the resonator.
  16.  
  17. Label and disconnect the fuel pressure regulator vacuum hose.
  18.  
  19. Remove the fuel rail bolts.
  20.  
  21. Remove the electrical connector from the camshaft position sensor.
  22.  
  23. Label and unplug all injector harness connectors. Push in the wire connector clip while pulling the connector away from the injector.
  24.  
  25. Remove the fuel inlet pipe at the rail. Use a back-up wrench on the fuel rail inlet fitting to prevent it from turning.
  26.  
  27. Carefully lift the rail from the cylinder head. Discard the injector O-rings.
  28.  

To install:

Whenever the fuel rail is disconnected from the fuel pipes, reconnect the fuel pipes to the rail at this time. Apply a few drops of clean engine oil to the male end of the fuel pipes before installing.

  1. Install the fuel pipe into the regulator. align the bracket to retain the return pipe. Tighten the bracket screw to 53 inch lbs. (6 Nm). Use a back-up wrench on the fuel rail inlet fitting to prevent it turning. Tighten the inlet pipe nut to 22 ft. lbs. (30 Nm).
  2.  

When ever there is not enough threadlocking material on the threads of the fuel outlet pipe bracket screw, apply Loctite262 to insure proper locking.

  1. Rotate the fuel injectors as required to avoid stretching the wiring harness.
  2.  
  3. Position the fuel rail over the cylinder head and connect the fuel injector electrical wiring. Place the fuel trail assembly into the cylinder head. Secure the retaining bolts to 19 ft. lbs. (26 Nm).
  4.  
  5. Attach the vacuum hose to the fuel pressure regulator.
  6.  
  7. If the front engine fuel pipes are being replaced, install a new O-rings and coat them with clean engine oil.
  8.  

Use a back-up wrench to prevent the female fitting from turning.

  1. Install the inlet and return pipe connections. Tighten the fuel pipe fittings to 20 ft. lbs. (27 Nm).
  2.  
  3. Install and secure the fuel pipe bracket clamp bolt to 106 inch lbs. (12 Nm).
  4.  
  5. Apply a few drops of clean engine oil to the vent hose and attach it to the bottom of the air cleaner resonator.
  6.  
  7. Apply a few drops of engine oil to the air cleaner resonator before installing it to the throttle body. Tighten the resonator clamp to 35-44 inch lbs. (4-5 Nm).
  8.  
  9. Install the air cleaner resonator bolts and secure to 89 inch lbs. (10 Nm).
  10.  
  11. Attach the air cleaner outlet duct to the resonator and tighten the duct clamp to 35-44 inch lbs. (4-5 Nm).
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Inspect the system for fuel leaks throughout the following steps:
    1. Turn the ignition switch to the ON position for two seconds.
    2.  
    3. Turn the ignition switch to the OFF position for ten seconds.
    4.  
    5. Turn the ignition switch to the ON position.
    6.  
    7. Check for fuel leaks.
    8.  

  16.  

3.0L and 3.3L Engines See Figures 4 and 5

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Fig. Fig. 4: Fuel rail assembly and injector locations-3.0L engine



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Fig. Fig. 5: View of the fuel rail mounting-3.3L engine

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Detach the fuel injector electrical connectors.
  6.  
  7. Remove the vacuum hose from the pressure regulator.
  8.  
  9. Disconnect the fuel feed land return lines from the fuel rail assembly, be sure to use a backup wrench on the inlet fitting to prevent turning. Remove and discard the O-ring(s).
  10.  
  11. Unfasten the fuel rail assembly retaining nut/bolts, then rove the fuel rail assembly and cover all openings tape to prevent dirt from entering.
  12.  
  13. Remove and discard the O-ring seals from the spray tip of each injector.
  14.  

To install:
  1. Lubricate new O-rings with clean engine oil, then install them on the injectors.
  2.  
  3. Position the fuel rail assembly on the intake manifold, the carefully push down on the rail to seal the injectors in the manifold. Secure the rail using the retaining nuts/bolts. Tighten to 20 ft. lbs. (27 Nm).
  4.  
  5. Put new O-ring(s) on the fuel lines, then install the lines. Be sure to use a backup wrench on the fuel rail inlet fitting to prevent it from turning.
  6.  
  7. Connect the vacuum hose to the pressure regulator.
  8.  
  9. Attach the injector electrical connectors.
  10.  
  11. Tighten the fuel filler cap, then connect the negative battery cable.
  12.  
  13. 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.
  14.  

3.1L Engine See Figure 6

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Fig. Fig. 6: View of the fuel rail assembly, injectors and fuel pressure regulator-3.1L SFI engine

  1. Disconnect the negative battery cable, then properly relieve the fuel system pressure.
  2.  
  3. Remove the intake manifold plenum (upper intake manifold) as outlined in Engine & Engine Overhaul .
  4.  
  5. Unfasten the fuel pipe bracket bolt, then remove the fuel pipes at the rail.
  6.  
  7. Remove the fuel pressure regulator from the rail.
  8.  
  9. Remove and discard the fuel feed and return pipe O-rings.
  10.  
  11. Detach the fuel injector electrical connectors.
  12.  

Be careful when removing the fuel rail assembly to avoid damage to the injector electrical connector terminals and spray tips. Prevent dirt and other debris from entering open lines and passages. Fittings should be capped and holes should be plugged during servicing.

  1. If applicable, disconnect the coolant temperature sensor wiring.
  2.  
  3. Unfasten the fuel rail retaining bolts, then remove the rail assembly from the engine.
  4.  
  5. Remove and discard the injector O-ring seals from the spray tip end of each injector. With the O-rings removed, the O-ring backup may slip off the injector. Keep the backup for reuse during installation.
  6.  

To install:
  1. Make sure the backups are on the injectors, then lubricate new injector O-rings with clean engine oil and install on the spray tip of each injector.
  2.  
  3. Install the fuel rail in the intake manifold. Tilt the assembly to install the injectors. Secure with the retaining bolts, then tighten the bolts to 7 ft. lbs. (10 Nm).
  4.  
  5. Attach the injector electrical connectors.
  6.  
  7. Put new O-rings on the fuel feed and return pipes, then install the pipes. Using a backup wrench on the fittings to prevent them from turning, tightening the fuel pipe nuts to 13 ft. lbs. (17 Nm).
  8.  
  9. Install any remaining components.
  10.  
  11. Connect the negative battery cable, then tighten the fuel filler cap.
  12.  
  13. 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.
  14.  
  15. Install the intake manifold plenum.
  16.  

 
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