Fuel Rail Assembly Replacement - Bank 1

FUEL RAIL ASSEMBLY REPLACEMENT - BANK 1

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.
2. Remove the water outlet tube.
3. Remove the battery cable junction block bracket bolt (1) from the power steering pump bracket.
4. Reposition the junction block and bracket.




5. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

IMPORTANT:
- After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
- Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

6. Remove the charged air cooler inlet duct connector (4) from the turbocharger.




7. Disconnect the fuel feed and return line quick connect fittings.
8. Remove the fuel line bracket nut.
9. Remove the fuel line bracket from the stud.
10. Remove the positive crankcase ventilation (PCV) hose/pipe.




11. Remove the air conditioning (A/C) compressor bolts.
12. Reposition the A/C compressor aside.




13. Remove the banjo bolt and washer from the fuel injection control module.
14. Remove the fuel feed pipe nuts/bolts.
15. Remove the fuel feed pipe.




16. Disconnect the fuel rail balance pipe from the fuel rails.
17. Remove the fuel rail balance pipe bolts.
18. Remove the fuel rail balance pipe.




19. Disconnect the fuel injector return hose from the return/junction block line.




20. Reposition the return/junction block hose clamps at the injection pump.
21. Remove the fuel hoses from the return/junction block.




22. Reposition the return/junction block hose clamp at the rear of the left fuel rail.
23. Remove the fuel hose from the fuel rail.
24. Remove the return/junction block fuel line clip bolts.
25. Remove the return/junction block and lines.




26. Remove the fuel pipe bracket bolts.
27. Remove the fuel pipe bracket.




28. Disconnect the fuel inlet pipe from the fuel rail.
29. Disconnect the fuel inlet pipe from the injection pump.
30. Remove the inlet fuel pipe.




31. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
32. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
33. Remove the left fuel injector pipes.

NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.




34. Remove the fuel rail bolts.
35. Remove the fuel rail and bracket.

INSTALLATION PROCEDURE




1. Install the fuel rail and bracket.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel rail bolts.

Tighten the bolts to 25 N.m (18 lb ft).




3. Install the fuel injector pipes.

NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.

Tighten the fittings to 41 N.m (30 lb ft).

4. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.




5. Remove the inlet fuel pipe.
6. Connect the fuel inlet pipe to the injection pump.
7. Connect the fuel inlet pipe to the fuel rail.

Tighten the fittings to 41 N.m (30 lb ft).




8. Install the fuel pipe bracket.
9. Install the fuel pipe bracket bolts.

Tighten the bolts to 25 N.m (18 lb ft).




10. Install the return/junction block and lines.
11. Install the return/junction block fuel line clip bolts.

Tighten the bolts 25 N.m (18 lb ft).

12. Install the fuel hose to the fuel rail.
13. Position the return/junction block hose clamp at the rear of the left fuel rail.




14. Install the fuel hoses to the return/junction block.
15. Position the return/junction block hose clamps at the injection pump.




16. Connect the fuel injector return hose to the return/junction block line.




17. Install the fuel rail balance pipe.
18. Connect the fuel rail balance pipe to the fuel rails.

Tighten the fittings to 41 N.m (30 lb ft).

19. Install the fuel rail balance pipe bolts.

Tighten the bolts 25 N.m (18 lb ft).




20. Install the fuel feed pipe.
21. Install the fuel feed pipe nut/bolt.

Tighten the nut/bolt to 25 N.m (18 lb ft).

22. Install the banjo bolt and washer to the fuel injection control module.

Tighten the bolt to 40 N.m (29 lb ft).




23. Position the A/C compressor aside.
24. Install the A/C compressor bolts.

Tighten the bolts to 50 N.m (37 lb ft).

25. Install the PCV hose/pipe.




26. Install the fuel line bracket to the stud.
27. Install the fuel line bracket nut.

Tighten the nut to 21 N.m (15 lb ft).

28. Connect the fuel feed and return line quick connect fittings.




29. Remove the tape from the turbocharger openings.

IMPORTANT: Lubricate the end of the duct prior to installation.

30. Install the charged air cooler inlet duct connector (4) to the turbocharger.
31. Tighten the charged air cooler inlet duct to turbocharger clamp (1).

Tighten the clamp to 6 N.m (53 lb in).




32. Position the junction block and bracket.
33. Install the battery cable junction block bracket bolt (1) to the power steering pump bracket.

Tighten the bolt to 9 N.m (80 lb in).

34. Install the water outlet tube.
35. Connect the negative battery cable.
36. Prime the fuel system. Refer to Fuel System Priming.
37. Start the engine. If the engine stalls, repeat the above step.
38. Once the engine starts, inspect for fuel leaks.