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Fuel Rail & Injectors: Installation

WARNING: This page is about a different car, the 2002 Pontiac Firebird and 2002 Chevrolet Camaro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Always install new injector "O" rings when servicing the fuel injectors. Lubricate the NEW injector "O" rings with clean engine oil. Install the "O" rings on the fuel injector. Install the fuel injector clip on the fuel injector. The fuel injector will click when the injector is installed correctly. Do not install the front injector on each side of the fuel rail at this time.
  2. Without the front fuel injectors on either side of the fuel rail, place the fuel rail assembly on the intake manifold. Install the front fuel injector on each side of the fuel rail. Install the fuel injector retaining clips on the front fuel injector on each side of the fuel rail.
  3. Seat the fuel injectors by hand. Tighten the fuel rail hold-down bolts to specification. See TORQUE SPECIFICATIONS  . Connect the fuel injector harness fasteners. Connect the fuel injector electrical connectors. Install the vacuum source to the intake manifold. Install the vacuum line to the vacuum switch from the fuel pipe bundle.
  4. Install the vacuum line from the vacuum source to the fuel pressure regulator. Connect the fuel feed and fuel return pipes by pushing the pipes onto the fuel rail tubes. Connect the MAP sensor electrical connector.
  5. Reconnect negative battery cable. Inspect for leaks by using the following procedure.
    • Turn ignition on for 2 seconds.
    • Turn ignition off for 10 seconds.
    • Turn ignition on.
    • Check for fuel leaks.
Fig 1: Removing Fuel Rail Assembly (3.8L)
G00112770Courtesy of GENERAL MOTORS CORP.


  1. Lubricate the new injector upper "O" ring seal with clean engine oil. Install the new injector "O" ring seal on the injector. Install a new retainer clip on the injector. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket.
  2. Lubricate the new lower injector "O" ring seals with clean engine oil. Install the new "O" ring seals on the spray tip end of each injector. Install the fuel rail assembly to the intake manifold. Apply a 0.020" (0.5 mm) bead of GM Threadlock (12345382 USA or 10953489 Canada) or equivalent to the threads of the fuel rail bolts.
  3. Install the fuel rail attaching bolts. Tighten the fuel rail attaching bolts to specification. See TORQUE SPECIFICATIONS  . Connect the injector electrical connectors. Install each connector on the proper injector in order to ensure correct sequential injector firing order. Rotate the injectors as required in order to avoid stretching the wire harness.
  4. Connect the electrical harness to the fuel rail brackets. Connect the accelerator cable to the throttle body. Connect the fuel feed hose to the fuel rail fuel pipe. Tighten the fuel filler cap. Connect the negative battery cable.
  5. Inspect for leaks by using the following procedure.
    • Turn ignition on for 2 seconds.
    • Turn ignition off for 10 seconds.
    • Turn ignition on.
    • Check for fuel leaks.
Fig 1: Removing Fuel Rail Assembly (5.7L)
G00112766Courtesy of GENERAL MOTORS CORP.
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