Fuel Rail: Service and Repair

REMOVAL PROCEDURE





Tools Required
^ J 34730-1A Fuel Pressure Gauge
^ J 37088-A Tool Set, Fuel Line Quick-Connect Separator

An eight digit identification number is stamped on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required.

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
3. 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.

NOTE:
^ Remove the fuel rail assembly carefully 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.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

4. Disconnect the fuel feed hose (2) from the fuel rail (1).




5. Disconnect the accelerator cable from the throttle body and the accelerator cable bracket (without traction control).
6. Move the accelerator cable aside.




7. Disconnect the electrical connectors from the fuel injectors. Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
8. Disconnect the electrical harness from the fuel rail brackets.
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 O-ring seals.

INSTALLATION PROCEDURE




1. Lubricate the new lower injector O-ring seals with clean engine oil.
2. Install the new O-ring seals on the spray tip end of each injector.
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 the Fastener Notice in Service Precautions.

5. Install the fuel rail attaching bolts.

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

6. 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.
7. Connect the electrical harness to the fuel rail brackets.




8. Connect the accelerator cable to the throttle body and the accelerator cable bracket (without traction control).




9. Connect the fuel feed hose (2) to the fuel rail fuel pipe (1).
10. Tighten the fuel filler cap.
11. Connect the negative battery cable.
12. Inspect for leaks.
12.1. Turn the ignition switch ON for 2 seconds.
12.2. Turn the ignition switch OFF for 10 seconds.
12.3. Turn the ignition switch ON.
12.4. Check for fuel leaks.
13. Perform the Idle Learn Procedure. Refer to PCM Idle Learn Procedure. PCM Idle Learn Procedure