GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 1998 🢒 Riviera 🢒 Engine 🢒 Engine Mechanical - 3.8L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

Tools Required
    •  J 34730 Fuel Pressure Gauge
    • J 37088-A Fuel Line Quick-Connect Tools

    Object Number: 180378 Size: SH
  1. Relieve the fuel pressure from the fuel system. Refer to the Fuel Pressure Relief .

    2. Object Number: 185558 Size: SH
  2. Clean the fuel rail assembly and connections.

    3. Object Number: 13858 Size: SH
  3. Remove the fuel feed (2), and return (1) quick-connect pipes from the fuel rail tubes. Refer to Metal Collar Quick Connect Fitting Service .

    4. Object Number: 207599 Size: SH
  4. Remove the vacuum hose from the fuel pressure regulator.

    5. Object Number: 180061 Size: SH
  5. Remove the vacuum hose(s) from the throttle body.

    6. Object Number: 211486 Size: SH
  6. Remove the ignition coil wires from the coil and retainer clips on top of super charger. Refer to Spark Plug Wire Harness Replacement .

    7. Object Number: 198404 Size: SH
  7. Remove the generator and rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.
  8. Remove the fuel injector electrical connectors from the fuel injectors.

    9. Object Number: 207599 Size: SH
  9. Remove the injector electrical harness clips holding harness to front of fuel rail.

    10. Object Number: 66405 Size: SH
  10. Remove the supercharger boost control solenoid vacuum hose(s).
  11. Remove the supercharger bypass valve actuator vacuum hose(s).
  12. Remove the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
  13. Remove the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .
  14. Remove the fuel rail hold-down bolts from the fuel rail.

    15. Important: When servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

  15. Remove the fuel rail with equal force on both sides of the fuel rail.
  16. Remove the fuel rail with equal force on both sides of the fuel rail.

Installation Procedure

    Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

    Notice: 

       • Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
       • Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
       • Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.


    Object Number: 12275 Size: SH
  1. The O-rings must be replaced on all components that are replaced.
  2. Lightly oil the fuel injector (2) O-rings with clean motor oil.

    3. Object Number: 12256 Size: SH
  3. Place the fuel rail assembly on the intake manifold.
  4. Seat the fuel injectors by HAND.
  5. Install the fuel rail hold-down bolts.

    6. Tighten
    Tighten the fuel rail hold-down bolts to 10 N·m (7 lb ft).

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Tighten
    Tighten the fuel rail hold-down stud to 25 N·m (18 lb ft).


    Object Number: 66405 Size: SH
  6. Install the supercharger bypass valve actuator (1). Refer to Supercharger Bypass Valve Actuator Replacement .
  7. Install the supercharger boost control solenoid (2). Refer to Boost Control Solenoid Replacement .
  8. Install the supercharger bypass valve actuator vacuum lines.
  9. Install the supercharger boost control solenoid vacuum lines.

    10. Object Number: 207599 Size: SH
  10. Install the generator and rear generator mounting bracket. Refer to Generator Replacement in Engine Electrical.
  11. Install the injector electrical harness clips holding harness to front of fuel rail.

    12. Object Number: 198404 Size: SH
  12. Install the fuel injector electrical connectors.

    13. Object Number: 211486 Size: SH
  13. Install the ignition coil wires to coil and retainer clips on top of super charger. Refer to Spark Plug Wire Harness Replacement .

    14. Object Number: 207599 Size: SH
  14. Install the vacuum hose to the fuel pressure regulator.

    15. Object Number: 180061 Size: SH
  15. Install the vacuum hose(s) to throttle body.

    16. Object Number: 13858 Size: SH
  16. Install the fuel feed (2) and return (1) pipes to the fuel rail tubes Refer to Metal Collar Quick Connect Fitting Service .
  17. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement .

    18. Tighten
    Tighten the nut to 2 N·m (18 lb in).

  18. Install the negative battery cable. Refer to Battery Cable in Engine Electrical.
  19. Inspect for leaks.
    20. 20.1. Turn the ignition switch to the On position for 2 seconds.
    20.2. Turn the ignition switch to the Off for 10 seconds.
    20.3. Turn the ignition switch to the On position.
    20.4. Check for fuel leaks.
  20. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Body and Accessories.