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Home >> Buick >> 2006 >> Lucerne CX >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 3.8L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure
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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.
NOTE:
  • 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.
    Fig 1: Locating Fuel Injector Components
    GM751184Courtesy of GENERAL MOTORS CORP.
  1. If replacing the fuel rail, perform the following steps otherwise proceed to step 6.
  2. Lubricate the NEW O-ring seals with clean engine oil.
  3. Install the NEW fuel injector upper and lower O-ring seals (2, 4) onto the injectors.
  4. Install the fuel injectors (3).
  5. Install the fuel injector retainers (1).
    6. Fig 2: Identifying Fuel Rail & Nuts
    GM1686316Courtesy of GENERAL MOTORS CORP.
  6. Lubricate the lower fuel injector O-ring seals with clean engine oil.
  7. Place the fuel rain into position and seat the fuel injectors by gently pressing down over the injectors.
    8. NOTE: Refer to Fastener Notice .
  8. Install the fuel rail nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    9. Fig 3: Locating Engine Harness Electrical Connectors
    GM1686317Courtesy of GENERAL MOTORS CORP.
  9. Position the engine harness over the engine.
  10. Install the engine harness retainers (2) to the fuel rail.
  11. Connect the engine harness electrical connectors (1) to the fuel injectors.
    12. Fig 4: View Of Right Side Exhaust Manifold & Rear Heated Oxygen Sensor (HO2S)
    GM1687609Courtesy of GENERAL MOTORS CORP.
  12. Connect the engine harness electrical connector to the HO2S pigtail.
    13. Fig 5: Identifying Engine Harness Clips
    GM1686289Courtesy of GENERAL MOTORS CORP.
  13. Install the engine harness retainers (1, 3) to the heat shield.
  14. Connect the engine harness electrical connector (2) to the EGR valve.
  15. Connect the engine harness electrical connector (4) to the EVAP solenoid.
  16. Install the engine harness retainers (2) to the fuel rail.
    17. Fig 6: Identifying Engine Harness Connectors
    GM1686320Courtesy of GENERAL MOTORS CORP.
  17. Connect the engine harness electrical connectors (1) to the fuel injectors.
    18. Fig 7: Identifying Engine Control Module Harness Connectors
    GM1686288Courtesy of GENERAL MOTORS CORP.
  18. Connect the engine harness electrical connector (3) to the MAP sensor.
  19. Connect the engine harness electrical connector (1) to the ignition control module wiring harness electrical connector (2).
    20. Fig 8: Identifying Throttle Actuator Harness Connector
    GM1686287Courtesy of GENERAL MOTORS CORP.
  20. Connect the engine harness electrical connector (2) to the ECT sensor.
  21. Connect the engine harness electrical connector (1) to the throttle actuator.
  22. Install the spark plug wire retainer to the fuel rail.
    23. Fig 9: Identifying Spark Plug Wires & Ignition Coils
    GM1686322Courtesy of GENERAL MOTORS CORP.
  23. Connect the spark plug wires to the ignition coils.
    24. Fig 10: Identifying Positive Crankcase Ventilation (PCV) Tube
    GM1685531Courtesy of GENERAL MOTORS CORP.
  24. Install the PCV tube to the intake duct and intake manifold.
    25. Fig 11: Locating Evaporative Emission (EVAP) Pipe Quick Connect Fitting
    GM1686302Courtesy of GENERAL MOTORS CORP.
  25. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  27. Inspect for leaks.
    1. Turn ON the ignition for 2 seconds.
    2. Then OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
  28. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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