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Fuel Rail & Injectors: Installation

WARNING: This page is about a different car, the 2002 Pontiac Grand Am, 2002 Oldsmobile Alero, and 2002 Chevrolet Malibu. 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. Install the fuel injector in the fuel rail with the connector facing upward.
  2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. Align the injectors by rotating the fuel rail forward. Carefully push the fuel injectors into the cylinder head ports. Install the fuel rail attaching bolts and tighten to specification. See TORQUE SPECIFICATIONS  .
  3. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place. Install the fuel supply and return pipes. Connect the vacuum pipe to the fuel pressure regulator. Install air cleaner outlet resonator, air cleaner intake duct and vent hose.
  4. 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.


CAUTION: Fuel injector is calibrated for a specific flow rate. Be sure to use the correct part number when ordering replacement fuel injectors. When replacing the fuel injector "O" rings, be sure to install the Brown "O" ring in the lower position. The fuel injector lower "O" ring uses a nylon collar called the "O" ring backup, to properly position the "O" ring on the fuel injector. Be sure to install the "O" ring backup, or the sealing "O" ring may move on the fuel injector when installing the fuel rail. If the sealing "O" ring is not seated properly, a vacuum leak is possible and driveability complaints may occur.
  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 in the fuel rail. Install the fuel injector clip on the fuel injector.
  2. Install the fuel rail assembly into the intake manifold. Tilt the rail assembly to install the injectors. Install the fuel rail attaching bolts and tighten to specification. See TORQUE SPECIFICATIONS  . Connect the coolant temperature sensor electrical connector. Install the injector electrical harness to the fuel rail.
  3. Connect the injector electrical connectors. Push the slide locks into the locked position. Connect the main injector harness electrical connector. Install the new "O" rings on the fuel feed pipe and fuel return pipe. Connect the fuel feed pipe to the fuel rail and tighten to specification.
  4. Connect the fuel return pipe to the fuel pressure regulator and tighten to specification. Install the engine compartment fuel pipe retainer bolt. Install the upper intake manifold gaskets on the manifold. Apply GM Thread Lock (12345382) to the threads of the bolts and tighten to specification.
  5. Install the MAP sensor bolts. Install the MAP sensor vacuum line. Connect the MAP sensor electrical connector. Install the vacuum hose to the fuel pressure regulator and the PCV. Connect TP sensor connector. Connect the IAC connector. Connect the coolant hoses from the throttle body.
  6. Install the EVAP canister purge solenoid. Install the electronic ignition coil and module assembly. Install the EGR pipe. Install the throttle cables and bracket to the throttle body. Install the air cleaner assembly. Install the brake vacuum pipe. Fill the cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEM. Connect the negative battery cable.
  7. 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.
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