Fuel Rail Assembly (DOHC): 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-rings seals with clean engine oil and install injectors into fuel rail.
With injectors pointing downward, install fuel rail assembly to intake manifold by lowering the fuel line end of the fuel rail into the cavity between the cam cover and intake manifold.
Apply Loctite 242(R) Threadlocker (P/N 21485277) or equivalent to the attachment bolt threads. Install fuel rail attachment bolts.
Torque:

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

Fig 1: Fuel Rail Attachment Bolts
Courtesy of GENERAL MOTORS CORP.

NOTE: Rotate #2 injector terminals approximately 15° from vertical towards front of engine. This will provide clearance between throttle cable and #2 injector wires. Clearance is necessary to prevent abrasion of wires.
Connect fuel injector electrical connectors. Push in until a click is heard and pull back to insure engagement.

Fig 2: Fuel Injector Electrical Connectors
Courtesy of GENERAL MOTORS CORP.
Install power steering support bracket.
Torque:

Power Steering Pump Brace-to-Block: 30 N.m (22 ft-lbs)
Connect accelerator cable to throttle body and to accelerator cable support bracket. Attach the accelerator control cable bracket.
Torque:

Accelerator Control Cable: 30 N.m (22 ft-lbs)

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 and male fuel return line connections. Attach the fuel feed line and pull back to confirm engagement. Attach the fuel return line and pull back to confirm engagement.
Install fuel line clip to bracket with attachment bolt (10 mm hex).
Torque:

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

Fig 3: Fuel Line Clip To Bracket
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 seconds.
2. Repeat step 1 twice.
3. Crank engine until it starts (maximum starter motor cranking time is 15 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 air tube and air filter cover.