Fuel Pressure Sensor/Switch: Service and Repair

Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement

Removal Procedure




1. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (High Pressure Side) (Fuel Pressure Relief (High Pressure Side)).
2. Disconnect the fuel injector wiring harness electrical connector (1) from the fuel injection fuel rail fuel pressure sensor.





Note: Do NOT reposition the foam insulator as damage to the insulator may occur.

3. Insert a 27 mm socket through the opening in the foam insulator (2) onto the fuel injection fuel rail fuel pressure sensor (1).





Note: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

4. Place a clean shop towel under the fuel injection fuel rail pressure sensor to fuel rail location.
5. Remove and discard the fuel injection fuel rail fuel pressure sensor (1).
6. Allow any fuel to drain from the fuel rail and pressure sensor location.
7. Dry the sealing cone in the fuel rail and the area around the sensor joint with a lint free cloth.
8. Inspect the sealing cone in the fuel rail. The surface should be free of fuel, debris, and burrs.

Installation Procedure

Note: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.

Note: Ensure that the fuel rail threads have been cleaned of any excess fuel, or the NEW fuel injection fuel rail fuel pressure sensor will NOT seal properly.




1. Lubricate the threads and the sealing cone in the fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
2. Lubricate the threads and sealing cone on the NEW fuel injection fuel rail fuel pressure sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
3. Install the NEW fuel injection fuel rail fuel pressure sensor hand tight.
4. Remove the NEW fuel injection fuel rail fuel pressure sensor, re-lubricate following steps 1 and 2 above.

Caution: Refer to Component Fastener Tightening Caution (Component Fastener Tightening Caution).

5. Install the NEW fuel injection fuel rail fuel pressure sensor (1) and tighten to 33 Nm (25 lb ft).




6. Connect the fuel injector wiring harness electrical connector (1) to the fuel injection fuel rail fuel pressure sensor.
7. Install a NEW high pressure fuel line. Refer to Fuel Feed Intermediate Pipe Replacement (Service and Repair).
8. Install the low side fuel pressure service port cap.
9. Tighten the fuel fill cap.
10. Inspect for fuel leaks using the following procedure:

1. Place a sheet of paper towel in between the bottom of the sensor and the top of the generator.
2. Start the vehicle and allow the vehicle to idle for approximately 5 minutes.
3. Shut the vehicle off.
4. Remove the paper towel and inspect the towel for wetting. If wetting is noted repeat steps 1 through 5.