GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 1996 🢒 Achieva 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

    Object Number: 17661 Size: SH
  1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the negative battery cable.

    3. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  3. Loosen the air cleaner outlet duct clamp.
  4. Remove the air cleaner outlet duct from air cleaner resonator.
  5. Loosen the air cleaner resonator clamp at the throttle body.
  6. Remove the bolts (1) attaching the resonator.
  7. Remove the air cleaner resonator (2) from the throttle body (3).
  8. Remove the crankcase vent hose to bottom of resonator, then remove the resonator.

    9. Object Number: 14133 Size: SH
  9. Remove the fuel pipe clamp bolt.
  10. Remove the vacuum hose at pressure regulator.
  11. Remove the fuel rail attaching bolts.
  12. Remove the fuel rail assembly (1) from cylinder head.
  13. Remove the injector electrical connectors. Push in wire connector clip, while pulling connector away from fuel injector.
  14. Remove the fuel inlet pipe at fuel rail. (Use a backup wrench on the fuel rail inlet fitting to prevent it from turning).
  15. Loosen fuel return pipe retaining bracket attaching screw (7). (Rotate retaining bracket (8) to allow fuel pipe to be removed).
  16. Remove the fuel return pipe from pressure regulator (11).
  17. Remove the fuel rail assembly.
  18. Remove the inlet and return pipe to fuel feed and return line connections.
  19. Remove the inlet and return pipe assemblies. Discard O-rings (9).

Installation Procedure

    Object Number: 14133 Size: SH

    Important: Apply a few drops of clean engine oil to the male end of the fuel pipes before installing.

  1. Whenever the fuel rail is disconnected from fuel pipes, reconnect fuel pipes to rail at this time.

    2. 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: Whenever there is not enough thread-locking material on the threads of the fuel outlet pipe bracket screw, apply Loctite® 262 to insure proper locking.

  2. Install the return pipe into regulator (11). (Align bracket to retain return pipe).

    3. Tighten

        • Tighten return pipe bracket screw (7) to 6.0 N·m (53 lb in).

           Important: Use a backup wrench on the fuel rail inlet fitting to prevent it from turning.

        • Tighten fuel inlet pipe nut to 30 N·m (22 lb ft).

    Important: Rotate fuel injector(s) as required to avoid stretching the wire harness.

  3. Position fuel rail (1) over cylinder head and connect fuel injector electrical connectors.
  4. Install the fuel rail assembly into cylinder head.
  5. Install the fuel rail assembly attaching bolts.

    6. Tighten
    Tighten fuel rail attaching bolts to 26  N·m (19 lb ft).

  6. Install the vacuum hose to fuel pressure regulator (11).
  7. If front (engine) fuel pipes are being replaced, install new fuel pipe O-rings (9), coated with clean engine oil.

    8. Important: Use a backup wrench to prevent female fitting from turning.

  8. Install the inlet and return pipe connections.

    9. Tighten
    Tighten fuel pipe fittings to 27 N·m (20 lb ft).

  9. Install the fuel pipe clamp bolt

    10. Tighten
    Tighten the bolt to 12 N·m (106 lb in).


    Object Number: 17661 Size: SH

    Important: Apply a few drops of clean engine oil to the vent hose before installing

  10. Install the crankcase vent hose to bottom of the air cleaner resonator.

    11. Important: Apply a few drops of clean engine oil to the air cleaner resonator before installing

  11. Install the air cleaner resonator (2) to throttle body (3).

    12. Tighten
    Tighten the air cleaner resonator clamp to throttle body 4-5 N·m (35-44 lb in).

  12. Install the air cleaner resonator attaching bolts (1).

    13. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  13. Air cleaner outlet duct to air cleaner resonator.

    14. Tighten
    Tighten the air cleaner outlet duct clamp 4-5 N·m (35-44 lb in).

  14. Install the negative battery cable.
  15. Inspect for fuel leaks through the following steps:
    16. 15.1. Turn the ignition switch to the ON position for two seconds.
    15.2. Turn the ignition switch to the OFF position for ten seconds.
    15.3. Turn the ignition switch to the ON position.
    15.4. Check for fuel leaks.