GM Storm/Spectrum 1985-1993 Repair Guide

Fuel Injectors/Fuel Rail Assembly

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REMOVAL & INSTALLATION



Except 1993 1.6L Engine

See Figures 1 and 2

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air duct assembly.
  6.  
  7. Disconnect the throttle cable at the throttle body, the throttle cable from the bracket and the TPS electrical connector.
  8.  
  9. Unplug the idle air control valve and the intake air temperature sensor electrical connectors.
  10.  
  11. Label and disconnect the 2 vacuum hoses, then disconnect the 2 coolant hoses at the throttle body.
  12.  
  13. Remove the 4 throttle body retaining bolts.
  14.  
  15. Remove the throttle body. Then remove and discard the gasket from the mating surface.
  16.  
  17. Tag and disconnect the 4 vacuum hoses at the plenum.
  18.  
  19. Disconnect the PCV valve at the plenum. Disconnect the ECM ground wires.
  20.  
  21. Remove the engine lift hook brackets, then remove the plenum support brackets.
  22.  
  23. Remove the 9 plenum retaining nuts and bolts, then remove the plenum assembly.
  24.  
  25. Unplug the 4 injector electrical connectors.
  26.  
  27. If the fuel rail is to be completely removed from the engine, disconnect the fuel lines. Using a backup wrench to prevent fuel rail/pressure regulator damage, disconnect the fuel pressure line from the rail and return line from the regulator.
  28.  
  29. Remove the fuel rail retaining bolts, then remove the rail/injector assembly from the engine.
  30.  
  31. If fuel injector removal from the fuel rail is necessary, slide the injector retaining clip along the fuel rail ledge away from the injector to disengage, then spread the clip open while pulling downward. Discard the clip after it has been removed. Remove the injector assemblies.
  32.  
  33. Remove the O-ring from the top and bottom of the injectors and discard them. If the injectors are not being removed from the rail, only the bottom O-rings must be replaced.
  34.  

To install:

Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be sure to order the identical part number that is inscribed on the old injector.

  1. Install new O-rings to the bottom (and if applicable to the top) of the injectors, then lubricate them with clean engine oil.
  2.  
  3. If removed, install the fuel injectors into the fuel rail. Install the new injector retaining clip. Be sure that the clip is parallel to the injector electrical connector.
  4.  

Be sure to install the injector assembly into the fuel rail injector socket, with the electrical connector and retaining clip facing outward. Line up the injector with the injector socket, push upward slowly to engage the retaining clip on the fuel rail ledge then push the injector all the way in to firmly seat it in the socket.

  1. Install the fuel rail/injector assembly to the engine and secure using the retaining bolts. Tighten the bolts to 19 ft. lbs. (26 Nm).
  2.  
  3. If disconnected, replace the O-rings seals, then connect the fuel lines and tighten using a backup wrench to prevent component damage.
  4.  
  5. Install the 4 wiring harness connectors to the injector terminals.
  6.  
  7. Install the plenum assembly. Install the 9 plenum retaining nuts and bolts. Install the plenum support brackets.
  8.  
  9. Install the engine lift hook brackets.
  10.  
  11. Reconnect the PCV valve at the plenum and the ECM ground wires.
  12.  
  13. Install the 4 vacuum hoses to the plenum.
  14.  
  15. Install the throttle body using a new gasket.
  16.  
  17. Install the 4 retaining bolts at the throttle body assembly. Torque the bolts 16 ft. lbs. (22 Nm).
  18.  
  19. Reconnect the 2 vacuum hose and the 2 coolant hoses to the throttle body.
  20.  
  21. Install the wiring harness connectors to the idle air control valve and the intake air temperature sensor and TPS terminals.
  22.  
  23. Reconnect the throttle cable at the throttle body and the throttle cable to the bracket.
  24.  
  25. Install the air duct assembly.
  26.  
  27. Reconnect the negative battery cable.
  28.  
  29. Cycle the ignition to build system pressure, then check for leaks.
  30.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the fuel rail assembly - Except 1993 1.6L engine



Click image to see an enlarged view

Fig. Fig. 2: Removing the fuel injector retaining clip - Except 1993 1.6L engine

1993 1.6L Engine

See Figures 3 and 4

  1. Relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Disconnect the PCV valve and hose from the plenum.
  4.  
  5. Disconnect the fuel supply line from the retainer bracket.
  6.  
  7. Disconnect the fuel return line from the pressure regulator.
  8.  
  9. Tag and remove the canister purge vacuum hoses from the plenum and fuel rail.
  10.  
  11. Disconnect the pressure regulator vacuum hose.
  12.  
  13. Unplug the wiring harness connectors from the fuel injectors.
  14.  
  15. Unplug the Intake Air Temperature (IAT) sensor connector, then reposition the harness away from the fuel rail.
  16.  
  17. Remove the plenum support bracket and fasteners from the passenger side of the plenum.
  18.  
  19. Using a 1 / 4 in. drive with an 11 in. extension and 12mm universal socket, remove the 2 fasteners with spacers for the fuel rail.
  20.  
  21. Remove the fuel injectors from the fuel rail and intake, then remove and discard the fuel injector O-rings.
  22.  
  23. If necessary, remove the fuel rail by sliding out towards the passenger side of the engine compartment.
  24.  

To install:

Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be sure to order the identical part number that is inscribed on the old injector.

  1. Install new O-rings to the bottom (and if applicable to the top) of the injectors, then lubricate them with clean engine oil.
  2.  
  3. If removed, slide the fuel rail in from the passenger side of the engine compartment.
  4.  
  5. Connect the fuel line to the pressure regulator.
  6.  
  7. Install the fuel injector assemblies to the fuel rail, then seat the rail and injectors to the intake.
  8.  
  9. With the socket, extension and drive used earlier, install the 2 fuel rail fasteners (with spacers) and tighten to 19 ft. lbs. (26 Nm).
  10.  
  11. Connect the vacuum hose to the fuel pressure regulator.
  12.  
  13. Install the canister purge vacuum hoses.
  14.  
  15. Connect the fuel pressure line.
  16.  
  17. Install the wiring harness connectors to the IAT sensor and the fuel injectors.
  18.  
  19. Install the PCV valve and vacuum hose.
  20.  
  21. Install the plenum support bracket to the passenger side of the plenum and tighten the fasteners.
  22.  
  23. Install air cleaner duct.
  24.  
  25. Connect the negative battery cable, then cycle the ignition to build system pressure and check for leaks.
  26.  



Click image to see an enlarged view

Fig. Fig. 3: Partial exploded view of the fuel rail assembly - 1993 1.6L engine



Click image to see an enlarged view

Fig. Fig. 4: Fuel injector assembly - 1993 1.6L engine

 
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