GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

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.

REMOVAL & INSTALLATION



2.3L Engine

See Figure 1



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Fig. Fig. 1: View of the fuel rail and related system components-2.3L engine

  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Detach the hoses at the front and side of the crankcase ventilation oil/air separator. Leave the vacuum hoses connected to the canister purge solenoid.
  6.  
  7. Unfasten the bolts connecting the crankcase ventilation oil/air separator and canister purge solenoid.
  8.  
  9. Disconnect the hose to the bottom of the separator, then remove the separator.
  10.  
  11. 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.
  12.  
  13. Remove the vacuum line at the pressure regulator. Remove the fuel rail assembly retaining bolts.
  14.  
  15. Push in the wire connector clip, while pulling the connector away from the injector.
  16.  
  17. Remove the fuel rail assembly and cover all openings with masking tape to prevent dirt entry.
  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 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 tread 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.
  8.  
  9. Turn the ignition to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Again, turn to the ON position and check for fuel leaks.
  10.  

2.8L, 3.1L, 3.4L and 3.8L Engines

See Figure 2, 3, 4 and 5



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Fig. Fig. 2: ...



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Fig. Fig. 3: ... then remove the fuel rail from the engine



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Fig. Fig. 4: Exploded view of the fuel rail and related components-3.1L (VIN T) engine shown



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Fig. Fig. 5: Fuel rail assembly-1995 3.4L engine shown

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve fuel system pressure, as outlined earlier in this information.
  4.  
  5. For 3.1L and 3.4L engines, remove the intake manifold plenum.
  6.  
  7. If equipped, remove the engine fuel pipe bracket bolt.
  8.  
  9. Disconnect the fuel feed line and return lines from the fuel rail assembly; be sure to use a backup wrench on the inlet fitting to prevent turning or refer to the procedure for quick-connect fittings, located earlier in this information. Remove and discard the fuel feed and return pipe O-rings.
  10.  
  11. For the 3.4L and 3.8L engines, disconnect the vacuum line from the pressure regulator. Remove the return line from pressure regulator.
  12.  
  13. Detach the electrical connectors from each fuel injector.
  14.  
  15. Unfasten the bolts retaining the fuel rail assembly to the intake manifold. Remove the fuel rail assembly and cover all openings with masking tape to prevent dirt entry.
  16.  

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. Position the fuel rail assembly to the intake manifold. Tilt the rail to install the injectors.
  2.  
  3. Install the retaining bolts and observe the following torque specifications:

    2.8L and 3.1L engines: Fuel rail retaining nuts to 89 inch lbs. (10 Nm).
     
    2.8L and 3.1L engines: Fuel feed line nut to 17 ft. lbs. (23 Nm).
     
    3.4L engine: Fuel rail retaining nuts to 89 inch lbs. (10 Nm).
     
    3.4L engine: Fuel feed line nut to 22 ft. lbs. (30 Nm). 20 Nm).
     

  4.  
  5. Attach the injector electrical connectors.
  6.  


CAUTION
To reduce the risk of fire and/or personal injury, always apply a few drops of clean engine oil to the male tube ends before connecting the fuel line quick-connect fittings. This will ensure proper reconnection and prevent a possible fuel leak. During operation, O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

  1. Lightly lubricate new feed and return pipe O-rings with clean engine oil, then install on the pipes. Connect the fuel feed and return pipes, either following the quick-connect fitting procedure located earlier in this information or using a back-up wrench to prevent the fittings from turning, depending upon application. If necessary, tighten to 13 ft. lbs. (17 Nm).
  2.  
  3. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  4.  
  5. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  6.  
  7. For the 3.1L engine, install the intake manifold plenum, as outlined in Engine & Engine Overhaul of this repair guide.
  8.  

 
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