GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 2000 🢒 Catera 🢒 Body and Accessories 🢒 Wiring Systems 🢒 Fuel Injector and Fuel Rail Replacement

Removal Procedure

    Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    2. Important: Mask off the intake ducts after removing the upper plenum. Entry of foreign objects can cause severe engine damage.

  2. Remove the intake plenum. Refer to Intake Plenum Replacement in Engine Mechanical.

    3. Notice: 

       • Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
       • Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

  3. Disconnect the fuel rail intermediate lines, supply-return. Then position the fuel rail intermediate lines away from the fuel rail .
  4. Remove the fuel rail bracket bolts near the fuel supply-return lines.
  5. Disconnect the fuel injector electrical connectors. Unclip the harness from the fuel rail and position it out of the way.
  6. Disconnect the fuel pressure regulators atmospheric vent hose.
  7. Remove the fuel rail attaching bolts from the intake manifold.

    8. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

  8. Use compressed air in order to blow dirt out of the area where the injectors enter the intake casting.
  9. Remove the fuel rail assembly.
  10. Remove the retainers from the fuel injectors.
  11. Remove the injectors from the fuel rail.

    12. Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

  12. Remove the O-rings from the injectors. Discard the O-rings.

Installation Procedure
  1. Lubricate the new injector O-rings with clean engine oil.
  2. Install the new injector O-rings on the injectors.
  3. Install the injectors to the fuel rail with the new retainer clips.
  4. Ensure that the injectors are aligned by orienting the electrical connectors perpendicular to the crankshaft centerline.
  5. Install the fuel rail with the injectors to the intake manifold.
  6. Install the fuel rail attaching bolts to the intake manifold.

    7. Tighten
    Tighten the fuel rail attaching bolts to 8 N·m (71 lb in).

  7. Reconnect the fuel pressure regulators atmospheric vent hose.
  8. Reconnect the fuel injector electrical connectors and the clip harness to the fuel rail.
  9. Install the fuel rail bracket bolts near the fuel supply-return lines.

    10. Tighten
    Tighten the fuel rail bracket bolts to 8 N·m (71 lb in).

  10. Reconnect the fuel rail intermediate lines, supply-return, to the fuel rail .

    11. Tighten
    Tighten the supply and return lines to 15 N·m (11 lb ft).

  11. Reinstall the intake plenum. Refer to Intake Plenum Replacement in Engine Mechanical.
  12. Connect the negative battery cable.
  13. Crank the engine for a few seconds. Turn OFF the engine if the engine starts.
  14. Check for fuel leaks.