Fuel Rail Assembly (SOHC): Installation

NOTE: When cleaning or servicing the fuel rail, care must be taken to assure that the plastic fuel rail surfaces that mate to the injector O-rings are not scratched.

Lubricate the new O-ring seals with clean engine oil and install injectors into fuel rail.
To install fuel rail assembly to intake manifold:
1. With injectors pointing upward, lower the fuel rail into the cavity between the cam cover and intake manifold.
2. Move rail towards power steering pump.
3. Rotate the injectors into a horizontal position. The fuel rail must be placed against the intake manifold runners to accomplish this.
4. Align injectors with their respective port holes.
5. Carefully push fuel injectors into holes, making sure they have seated on intake manifold.
  
  Fig 1: Installing Fuel Injector Rail
  Courtesy of GENERAL MOTORS CORP.
Install fuel rail attaching bolts.
Torque:

Fuel Rail Attachment Bolts: 12 N.m (9 ft-lbs)

Fig 2: Fuel Rail Attaching Bolts
Courtesy of GENERAL MOTORS CORP.
Connect fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.

Fig 3: Fuel Injector Electrical Connectors
Courtesy of GENERAL MOTORS CORP.
Connect accelerator cable to throttle body and to accelerator cable support bracket. Attach the accelerator control cable bracket.
Torque:

Accelerator Control Cable Bracket-to-Intake Manifold (L24): 30 N.m (22 ft-lbs)
Connect PCV valve hose.
CAUTION: LUBRICATE WITH CLEAN ENGINE OIL THE MALE END OF THE FUEL RAIL THAT CONNECTS WITH THE FUEL SUPPLY LINE. FIRMLY PRESS ON FEMALE COUPLER UNTIL A CLICK IS HEARD, THEN PULL BACK TO CONFIRM ENGAGEMENT, PINCHED, KINKED OR DAMAGED FUEL LINES MUST BE REPLACED.

NOTE: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.
Lubricate with clean engine oil the male fuel feed line connection. Attach the fuel feed line and pull back to confirm engagement.
Install fuel line retainer clip attachment screw (10 mm hex).
Torque:

Fuel Line Retainer Clip: 4 N.m (35 in-lbs)

Fig 4: Fuel Line Retainer Clip Attachment Screw
Courtesy of GENERAL MOTORS CORP.
Connect negative battery terminal.
Torque:

Battery Terminal Bolts: 17 N.m (13 ft-lbs)
Prime fuel system.
1. Cycle ignition on for 5 seconds and then off for 10 seconds.
2. Repeat step 1 twice.
3. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
4. If engine does not start, repeat steps 1- 3 .
With engine off and ignition on, pressurize the fuel system and check for leaks.
Install intake tube and air filter cover.