Fuel Rail: Service and Repair
FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
An eight digit identification number is located on the fuel rail assembly. Refer to this model identification number if servicing or pan replacement is required.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Before removal, clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak fuel rails in liquid cleaning solvent.
3. Disconnect the generator harness connector (1).
4. Disconnect the Evaporative Emission (EVAP) purge valve harness connector (4).
5. Disconnect the Throttle Position (TP) sensor harness connector (2).
6. Disconnect the electronic throttle control (ETC) harness connector (3).
7. Remove the upper engine wire harness bracket studs and position the upper engine wire harness aside.
8. Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
9. Pull the top portion (2) of the injector connector up. Do not pull the top portion of the connector past the top of the white portion (1).
10. Push the tab (1) on the lower side of the injector connector in order to release the connector from the injector.
11. Repeat step 9 and step 10 for each injector connector.
NOTE: Refer to Removing Fuel Rail Assembly Notice in Service Precautions.
12. Disconnect the fuel feed pipe (1) and the return pipe (2) from the fuel rail.
13. Disconnect the fuel pressure regulator vacuum line (1).
14. Remove the fuel rail attaching bolts (3).
15. Remove the fuel rail assembly (1).
16. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3).
17. Discard the O-ring seals.
INSTALLATION PROCEDURE
1. Lubricate the new lower injector O-ring seals (4) with clean engine oil.
2. Install the new O-ring seals (4) on the spray tip end of each injector (3).
3. Install the fuel rail assembly to the intake manifold.
4. Apply a 5 mm (0.020 in.) band of GM P/N 12345382 threadlock or equivalent, to the threads of the fuel rail bolts.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Install the fuel rail attaching bolts (3).
Tighten
Tighten the bolts to 12 N.m (106 lb in).
6. Connect the fuel pressure regulator vacuum line (1).
7. Connect the fuel feed pipe (1) and the return pipe (2) to the fuel rail.
8. Connect the injector electrical connectors.
^ Install each connector on the proper injector in order to ensure correct sequential injector firing order.
^ Rotate the injectors as required in order to avoid stretching the wire harness.
9. Install the upper engine wire harness bracket.
10. Install the retainer studs to the upper engine wire harness.
Tighten
Tighten the studs to 10 N.m (89 lb in).
11. Connect the generator harness connector (1).
12. Connect the EVAP purge valve harness connector (4).
13. Connect the Throttle Position (TP) sensor harness connector (2).
14. Connect the electronic throttle control (ETC) harness connector (3).
15. Tighten the fuel filler cap.
16. Connect the negative battery cable.
17. Inspect for leaks using the following procedure:
17.1. Turn ON the ignition, with the engine OFF for 2 seconds.
17.2. Turn OFF the ignition for 10 seconds.
17.3. Turn ON the ignition, with the engine OFF.
17.4. Inspect for fuel leaks.