Fuel Rail

myowneq · 10-24-2010, 05:36 AM

Hello Everyone,

I just replaced the lower intake manifold gasket on my 02 Alero.

I did a complete teardown based off the Haynes manual and was able to put everything back together. When I tried to crank the car up, I found I was spilling gas. With just myself around, it seemed like it was coming from the back right fuel injector. So, to the dealership to get newer orings and upper gaskets.

So I tore down again, really greased the FI orings well, and put everything back together. And I'm still getting a decent leak. So with my wonderful assistant (the wife) cranking the engine, it took a second to see exactly where it's coming from.

It's coming from the fuel inlet line where it goes into the backside of the fuel rail. I took the engine apart yet again (I'm getting pretty good at this, 20 minutes), and looked at the inlet line. It looks like there should be an ORing on there. I don't remember seeing one there.

My Haynes manual doesn't state anything and I can't find anything around the various car parts websites. Am I missing something? Does anyone have a suggestion?

Thanks,
Timothy

[ion] C2 · 10-24-2010, 09:51 AM

Common question. IIRC there was an o-ring, it must've fell out during disassembly.

BlackJack · 10-24-2010, 09:55 AM

3400 V6 definitely has an o-ring where the fuel line fitting screws into the rail. If it doesn't, it either fell off, or is stuck inside the rail. If it's stuck inside the rail, you must locate and remove it before putting on the new o-ring. Normal place for this o-ring is on the fuel line fitting, that's where it should stay when you remove the fuel line.

myowneq · 10-24-2010, 11:22 AM

It looked like there was a spot there for one. I'll take another look today and see if I can find it.

Thanks, I appreciate it.

Timothy

-Alero- · 10-24-2010, 10:36 PM

lol same thing happened to me a few years ago

zzyzzx · 10-25-2010, 10:48 AM

Same thing almost happened to me earlier this year, except I knew there had to be a gasket there and searched before I out it back togather. I eventually found a brown O ring under the car. So look for a brown O ring (the black O ring goes in the front).

This thread is complete with pics that show the brown fuel line O ring in the back.

Redog · 10-25-2010, 03:20 PM

I never saw these rings when I took my rail off

Guess I was lucky

alerored04 · 10-25-2010, 04:22 PM

This happens to me alot. They tear in half and fall off when you remove the line then you freak out because you cannot find all the pieces. I always use a random set of fuel safe orings. There is usually one in those bulk packs of assorted sizes that fits correctly. The first time I did this I got the single oring at the stealership. It was $12!

cherrington17 · 10-25-2010, 04:44 PM

Thankfully, every time I removed mine (twice) the O rings stayed in place. Side stepped a bullet on that one.

myowneq · 10-25-2010, 10:14 PM

Yup, dealership charges $12 for this oring.

If I had time to spend to find an aftermarket replacement, I'da been looking.

So got the oring installed, and no more fuel leak. At least at that point. Had another at the regulator. Easy fix. Removed line and reseated. No leak after that.

Then, there was the coolant line Oring. That one was $5 or 6. But now I have a whole nother issue if ya'll are bored. It's in a new topic.

Thanks for all the help ya'll.

Timothy