Replacing Fuel Intake Spider In Gmc Safari: Step-By-Step Guide

The fuel injector spider on a 1996 GMC Safari may need to be replaced if the engine is hesitating and lurching. This is a common problem with this model, as the original design has a wire inside the fuel hose, which can become worn out over time. The replacement process involves removing the upper intake and can be challenging due to access issues. It is possible for a marginally knowledgeable person to replace the fuel injector spider by following online instructions and videos, but it may take several hours to complete the task.

How to change intake fuel spider on 1996 GMC Safari

Diagnose a faulty fuel injection spider

To diagnose a faulty fuel injection spider, look out for the following signs:

• Engine misfires – This can cause the engine to sputter and vibrate.
• Rough idling – Your vehicle may sputter and shake when you're stopped at a sign or in traffic.
• Poor fuel economy – You may need to fill up your gas tank more often than usual.
• Unsteady RPM needle – The needle on the tachometer may move unprompted, indicating changes in RPM when your car isn't switching gears.
• Engine fails to start – If the engine isn't receiving its crucial combination of air and fuel, it may not start.
• Check Engine Light comes on – This could mean a number of things, but a flashing "Check Engine" light could indicate a dirty or malfunctioning fuel injector.
• Fuel leaks – If you notice wetness around the fuel rail area or smell fuel, you may have a fuel leak.

If you experience any of these issues, it's important to have your vehicle checked by a qualified mechanic to determine the exact cause and perform any necessary repairs or replacements.

Prepare for the replacement

First, you will need to source the replacement part. The fuel injector spider for the GMC Safari is available from a variety of retailers, including RockAuto, O'Reilly Auto Parts, and Delphi. The price of the part ranges from $197 to $450, depending on the brand and retailer.

In addition to the spider, you will also need to purchase a new intake manifold gasket. This is available from RockAuto for $26.79.

As for tools, you will need a deep 10mm socket, a ratchet, an 8mm socket, a small extension for the ratchet, a knuckle fitting, a 5/8" open-end wrench, a flat-blade screwdriver, and needle-nose pliers. You may also find it helpful to have a torque socket wrench. It is also recommended to have some WD-40, gasket sealant, plastic gloves, and a light for working in tight, dark spaces.

Before beginning the replacement, it is important to have a clear and organised workspace. Park your GMC Safari in a well-lit area, ideally in a garage or under a carport, to protect from the elements. Gather all the tools and parts you will need and lay them out within easy reach.

Finally, you will need to set aside enough time to complete the job. Depending on your level of experience and the specific model of your GMC Safari, the replacement process can take anywhere from 3.5 to 20 hours. For a novice mechanic, it is better to overestimate the time required, so plan for a full day or even a weekend to complete the job.

Remove the fuel lines

Removing the Fuel Lines

The first step is to relieve the fuel system pressure. To do this, locate the fuse for the fuel pump and remove it. Start the engine and let it run until it stalls. Crank the engine for a few more seconds to make sure the fuel pressure is relieved.

Now, you can remove the fuel lines. First, disconnect the negative battery cable. Then, locate the fuel lines that are connected to the fuel spider. There should be two lines, one on each side of the spider. Using a wrench, loosen the fittings that secure the fuel lines to the spider. Be careful not to strip the threads on the fittings. Once the fittings are loose, gently pull the fuel lines away from the spider. You may need to wiggle them a bit to get them free.

Place a clean rag under the fuel lines to catch any fuel that may spill out. Also, be very careful not to damage the O-rings on the fuel lines. These O-rings are important for sealing the connection between the fuel lines and the spider, so they need to be in good condition.

Set the fuel lines aside in a safe place where they won't be damaged or contaminated. You may want to label them to make sure they are reinstalled in the correct position.

Now that the fuel lines are removed, you can proceed with the rest of the fuel spider replacement procedure. Remember to work carefully and refer to a repair manual or seek professional help if you are unsure about any steps.

Remove the intake manifold

The first step is to disconnect the negative battery cable. Then, drain the coolant from the radiator by opening the petcock valve. Next, remove the air cleaner assembly, the throttle body, and the air intake tube. You will also need to remove the EGR valve, the cruise control cable, and the distributor.

Now, disconnect the fuel lines and the electrical connectors from the fuel injectors. Remove the valve cover and the rocker arm assembly. You will also need to remove the engine oil dipstick and tube, as well as the alternator.

At this point, you should be able to remove the intake manifold. Start by removing the bolts that secure the manifold to the cylinder head. Carefully lift the manifold off the engine, making sure not to damage the fuel injectors or the gasket.

Once the manifold is removed, you can replace the fuel injector spider. Finally, reinstall the intake manifold and all the components that were previously removed.

Install the new spider

Now that you have removed the old spider, it's time to install the new one. This process will involve carefully placing the new spider into position and reconnecting the necessary components. Here is a step-by-step guide to help you through the installation process:

• Prepare the new spider: Take your new spider assembly and ensure that it is properly cleaned and free of any debris. You may need to refer to the instructions that came with your specific spider kit for this step.
• Position the new spider: Carefully lower the new spider into place, ensuring that it is properly aligned with the mounting points. The spider should fit snugly into the space vacated by the old spider.
• Secure the new spider: Using the appropriate hardware, secure the new spider in place. Make sure to tighten any bolts or fasteners securely, but be careful not to over-tighten and risk damaging the new spider.
• Reconnect the fuel lines: Now, you will need to reconnect the fuel lines to the new spider. This process should be done carefully to avoid any leaks. Ensure that the lines are securely attached and there is no fuel leakage.
• Reconnect electrical connectors: Locate the electrical connectors that were previously disconnected and carefully plug them back into the new spider. Ensure that they are securely connected.
• Reinstall the upper intake manifold: This step will involve placing the upper intake manifold back into position and securing it with the appropriate bolts or fasteners. Make sure that all gaskets or seals are properly aligned and intact to prevent any leaks.
• Reattach any other components: Depending on how much you had to disassemble to access the spider, you may need to reattach other components such as the throttle body, cruise control cable, or AC compressor.
• Check for leaks: Before starting the engine, it is important to check for any fuel or vacuum leaks. Carefully inspect all connections and components for any signs of leakage. If any leaks are found, tighten the connections or replace any faulty components.
• Start the engine: Once you are satisfied that everything is properly connected and secured, you can attempt to start the engine. If the engine starts and runs smoothly, your new spider installation was successful!

By following these steps, you should be able to successfully install the new fuel intake spider on your 1996 GMC Safari. Take your time with each step, and don't be afraid to refer to online resources or seek assistance if needed.

Frequently asked questions