Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT) VIN V W/ Direct Fuel Injection

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LLT)

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027 - LP1, LY7) (Fuel Pressure Relief (With CH 48027) (LY7) VIN 7 W/O Direct Fuel Injection)Fuel Pressure Relief (Without CH 48027 - LP1, LY7) (Fuel Pressure Relief (Without CH 48027) VIN 7 W/O Direct Fuel Injection)Fuel Pressure Relief (With High Pressure Pump - LLT) (Fuel Pressure Relief (With High Pressure Pump (LLT) VIN V W/ Direct Fuel Injection) .
2. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement (Cross Vehicle Brace Replacement) .
3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement (LLT) (Service and Repair) .
4. Remove the intake manifold. Refer to Intake Manifold Replacement (Service and Repair) .
5. Remove the foam insulator from the fuel rails.




6. Disconnect the fuel injector wiring harness electrical connector (1) from the fuel injectors, fuel rail and fuel pressure sensor.
7. Remove the high pressure fuel sensor. Refer to Fuel Pressure Sensor Replacement (LLT) (Service and Repair) .
8. Remove the High pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement (LLT) (Service and Repair) . Discard this pipe.
9. Remove the fuel rail crossover pipe. Refer to Fuel Injection Fuel Rail Crossover Tube Replacement (LLT) (Fuel Injection Fuel Rail Crossover Tube Replacement (LLT) VIN V W/ Direct Fuel Injection) . Discard this pipe.




10. Remove the fuel rail bolts (1).
11. Carefully remove the bank one fuel rail (2) from the engine. Lift the rear of the rail to ease removal.
12. Remove and discard the direct fuel injector hold down clamps.

Important: The direct fuel injectors must be rebuilt whenever the injector has been released from the fuel rail or cylinder head.


13. Once the fuel rail is removed, remove the fuel injectors and rebuild them. Refer to Fuel Injector Replacement (LLT) (Service and Repair) .



Installation Procedure





1. Install the rebuilt direct fuel injectors (1) to the cylinder heads. Refer to Fuel Injector Replacement (LLT) (Service and Repair) .
2. Install new direct injector hold down clamps to the Injector.




3. On a new fuel rail, Lubricate the fuel injector cups with silicon free engine oil GM P/N 12345610 (Canadian P/N 9931930 or equivalent.
4. Carefully place the fuel rail (2) into position. Placing the front into the fuel rail over the front injector and rotating the rear downward.
5. Install the 2 outer fuel rail bolts in first, then the 2 inner bolts, hand tight.





Notice: Refer to Fastener Notice (Fastener Notice) .

6. Tighten the fuel rail bolts in the sequence shown.

1. Tighten the bank 1 fuel rail bolts first pass to 12 N.m (106 lb in).
2. Tighten the bank 1 fuel rail bolts final pass to 23 N.m (17 lb ft).


7. Install a NEW fuel rail crossover pipe. Refer to Fuel Injection Fuel Rail Crossover Tube Replacement (LLT) (Fuel Injection Fuel Rail Crossover Tube Replacement (LLT) VIN V W/ Direct Fuel Injection) .
8. Install a NEW High pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement (LLT) (Service and Repair) .
9. Install the high pressure fuel sensor(1). Refer to Fuel Pressure Sensor Replacement (LLT) (Service and Repair) .




10. Connect the fuel injector wiring harness electrical connector (1) to the fuel injectors, fuel rail and fuel pressure sensor.
11. Inspect for fuel leaks using the following procedure:

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

12. Install the foam insulator from the fuel rails.
13. Install the intake manifold. Refer to Intake Manifold Replacement (Service and Repair) .
14. Install the fuel pipe shield. Refer to Fuel Pipe Shield Replacement (LLT) (Service and Repair) .
15. Install the low side fuel pressure service port cap.
16. Install the fuel tank cap.
17. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement (Cross Vehicle Brace Replacement) .