Fuel Rail Installation
Fuel Rail Installation1. Place the NEW fuel rail assembly into position.
A. Align the fuel injectors to the fuel injector bores in the intake manifold.
B. Align the fuel injector assembly bracket to the engine lift bracket (Aurora); or EGR valve stud (Cadillac).
C. Apply pressure to fuel rail assembly to seat fuel injectors into fuel injector bores in the intake manifold.
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.
Important
Steps 2-8 MY 1995-97 Cadillac ONLY.
2. Install the nut retaining the fuel rail assembly bracket to the EGR stud.
Tighten the nut retaining the fuel rail assembly bracket to the EGR stud to 8 Nm (71 lb in).
3. Install the fuel rail injector sight shield spacers and studs.
Tighten the fuel injector sight shield studs to 12 Nm (106 lb in).
4. Align the throttle body heater pipe onto the fuel injector sight shield studs and install any retainers onto the fuel injector sight shield studs.
5. Connect the fuel injector wiring harness to the 8 fuel injectors and reinstall the fuel injector wiring harness.
6. Install and connect the NEW fuel pressure regulator hose to the fuel regulator and the vacuum port of the intake manifold.
7. Install and connect the brake booster hose.
8. Install and connect the [1][2]PCV rear hose.
Important
Steps 9-10 MY 1997 Cadillac ONLY).
9. Install and connect the [1][2]PCV front hose.
10. Install and connect the EVAP tube between the intake manifold adapter and the EVAP solenoid.
Important
Steps 11-15 MY 1995-97 Aurora ONLY.
11. Install the fuel rail injector sight shield spacers and studs.
Tighten the fuel rail injector sight shield studs to 12 Nm (106 lb in).
12. Install the bolt retaining the fuel rail assembly bracket to the engine lift bracket.
Tighten the fuel rail assembly bracket bolt to 6 Nm (53 lb in).
13. Connect the fuel injector wiring harness to the 8 fuel injectors and reinstall the fuel injector wiring harness.
14. Connect the NEW fuel regulator hose to the fuel regulator and the vacuum port on the intake manifold.
15. Install the [1][2]PCV rear hose.
16. Apply dielectric grease, GM P/N 12345579 (Canadian P/N 1974984) to each spark plug boot. Route and connect the front spark plug wires to the front spark plugs.
Important
Conduit installed in next step may be obtained locally if conduit ID and underhood temperature specifications are equivalent.
17. Install wire conduit, GM P/N 8919354 or equivalent, over each of the front spark plug wires where the spark plug wires lay across the fuel rail on both sides (approximately 6 feet required per vehicle).
^ Between the spark plug boot and the retainer in the center of the intake manifold, add a 300 mm (12 in) section of conduit on each of the left side spark plug wires.
^ Between the retainer in the center of the intake manifold and the conduit already installed, add the following sections of conduit on each left side spark plug wires:
^ 230 mm (9 in) on the number 2 spark plug wire
^ 150 mm (6 in) on the number 4 spark plug wire
^ 110 mm (4.5 in) on the number 6 and 8 spark plug wire
Important
Step 18 MY 1995-97 Aurora ONLY.
18. Install the fuel line connections.
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 0-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.
19. Clean the quick-connect fittings.
Caution
In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the 0-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
20. Apply a few drops of clean engine oil to the male ends of the engine fuel rail inlet and outlet pipes.
21. Connect the quick-connect fittings to the fuel rail. Push both sides of the fitting together to cause the retaining tabs/fingers to snap into place.
22. Pull on both sides of the fitting to ensure connection is secure once installed.
Important
Steps 23-30 MY 1995-97 Cadillac ONLY.
23. Install the retainers (4, 5) onto the quick-connect fittings of each fuel line.
24. Place the cruise control servo into position.
25. Connect the cruise control servo cable to the throttle body cruise control servo cam.
26. Connect the vacuum hoses to the cruise control servo.
27. Install the cruise control servo bracket bolts.
Tighten the cruise control servo bracket bolts to 12 Nm (106 lb in).
28. Position the vacuum hoses into the retainer holding the vacuum hoses onto the cruise control servo bracket.
29. Connect the transmission vent tube to the retainer on the cruise control servo bracket.
30. Connect the vacuum manifold to the intake manifold adapter.
31. Connect the negative battery cable.
32. Tighten the negative cable bolt at the battery.
Tighten the negative cable bolt to 15 Nm (11 lb ft).
33. Check for fuel leaks.
A. Turn the ignition switch ON for 2 seconds.
B. Turn the ignition switch OFF for 10 seconds.
C. Turn the ignition switch ON.
D. Check for fuel leaks.
E. Start the vehicle and allow engine to reach operating temperature while observing for fuel leaks.
34. Install the fuel injector sight shield.
35. Install the 4 fuel injector sight shield nuts.
Tighten the fuel injector sight shield nuts to 3 Nm (27 lb in).
36. Close the hood and reset the customer's radio setting.