Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE
An eight digit identification number is located on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required.
1. Remove the engine cover.
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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.




4. Disconnect the generator harness connector (1).
5. Disconnect the (EVAP) purge solenoid harness connector (4).
6. Disconnect the Throttle Position (TP) sensor harness connector (2).
7. Disconnect the electronic throttle control (ETC) harness connector (3).
8. Remove the upper engine wire harness bracket studs and position the upper engine wire harness aside.
9. Remove the Secondary Air Injection (AIR) crossover pipe, if applicable.




10. Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
11. 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).




12. Push the tab (1) on the lower side of the injector connector in order to release the connector from the injector.
13. Repeat steps 11 and 12 for each injector connector.

NOTE: Refer to Removing Fuel Rail Assembly Notice in Service Precautions.




14. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.




15. Disconnect the fuel pressure regulator vacuum line (1).




16. Remove the fuel rail attaching bolts (3).
17. Remove the fuel rail assembly (1).




18. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3).
19. 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.

Tighten
Tighten the bolts to 12 N.m (106 lb in).




6. Connect the fuel pressure regulator vacuum line (1).




7. Connect the fuel teed and return pipes (1 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 tiring order.
^ Rotate the injectors as required in order to avoid stretching the wire harness.
9. Install the Secondary Air Injection (AIR) crossover pipe, it applicable.
10. Install the upper engine wire harness bracket.
11. Install the retainer studs to the upper engine wire harness.

Tighten
Tighten the nut to 10 N.m (89 lb in).

12. Reconnect the generator harness connector (1).
13. Reconnect the (EVAP) purge solenoid harness connector (4).
14. Reconnect the Throttle Position (TP) sensor harness connector (2).
15. Reconnect the electronic throttle control (ETC) harness connector (3).
16. Tighten the fuel filler cap.
17. Connect the negative battery cable.
18. Inspect for leaks:
18.1. Turn ON the ignition for 2 seconds.
18.2. Turn OFF the ignition for 10 seconds.
18.3. Turn ON the ignition.
18.4. Inspect for fuel leaks.
19. Install the engine cover.