Fuel Injector and Fuel Rail Replacement

Fuel Injector and Fuel Rail Replacement

Removal Procedure






Caution: Refer to Battery Disconnect Caution.

1. Disconnect the negative battery cable.

Notice:
* Carefully remove the fuel rail assembly in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.

* Prevent dirt and other contaminants from entering the open pipes and passages. Cap the fittings and plug the holes when servicing the fuel system.

Remove the engine sight shield.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief. Fuel Pressure Relief
3. 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 the fuel rail in liquid cleaning solvent.




4. Remove the engine compartment fuel line.
5. Disconnect the engine compartment evaporative emission (EVAP) line from the chassis EVAP line.
6. Disconnect the fuel injector electrical connectors. Identify the connectors to their corresponding injectors in order to ensure the correct sequential injector firing order after reassembly.
7. Remove the fuel injector wiring harness retainers from the fuel rail.




8. Note the location of the fuel rail ground strap (1) on the intake manifold. The fuel rail ground strap must be installed during assembly.




9. Remove the fuel rail attaching bolts.
10. Remove the fuel rail assembly.
11. Remove the injector lower O-ring seal from the spray tip end of each injector.
12. Discard the lower O-ring seals.




13. Remove the fuel injectors, if necessary.
14. Release the injector retainer clip.
15. Remove the infector from the fuel rail.
16 Remove the upper O-ring seal.

Installation Procedure




1. Install the fuel injectors, if previously removed.
2. Lubricate the upper O-ring seal with clean engine oil.
3. Install the fuel injector to the fuel rail with the electrical connector facing outward.
4. Secure the injector retainer clip.




5. Note the location of the fuel rail ground strap (1) on the intake manifold. The fuel rail ground strap must be installed during assembly.




6. Lubricate the new lower injector O-ring seals with clean engine oil.
7. Install the new O-ring seals on the spray tip end of each injector.

Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

8. Install the fuel rail assembly to the intake manifold.
9. Apply a 5 mm (0.02 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock or equivalent to the threads of the fuel rail bolts.

Notice: Refer to Fastener Notice.

10. Install the fuel rail attaching bolts.

Tighten the fuel rail attaching bolts to 10 N.m (89 lb in).

11. Install the fuel injector wire harness retainers to the fuel rail.
12. Connect the fuel injector electrical connectors.

* Install each connector on the proper injector in order to ensure the correct sequential injector firing order.
* Rotate the injectors as required in order to avoid stretching the injector wiring harness.




13. Connect the engine compartment EVAP line to the chassis EVAP line.
14. Install the engine compartment fuel line.




15. Connect the negative battery cable.
16. Perform the following procedure in order to inspect for leaks:

1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Inspect for fuel leaks.

17. Install the engine sight shield.