Fuel Rail: Service and Repair

Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

Note: An 8-digit identification number is located on the fuel rail. Refer to this model identification number if servicing or part replacement is required.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).




2. Disconnect the fuel feed pipe (3) from the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
3. Remove the intake manifold. Refer to Intake Manifold Replacement (Service and Repair).
4. Before removal, clean the fuel rail assembly and the cylinder head 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.




5. Disconnect the fuel injector harness in-line connector (3) from the engine wire harness.
6. Remove the fuel injector harness in-line connector (3) from the rocker cover.
7. Remove the fuel rail attaching bolts (2).

Caution:
* 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.

Note: Before removal, clean the fuel rail 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.

8. Remove the fuel rail assembly (1).




9. Remove the injector lower O-ring seal from the spray tip end of each injector.
10. Discard the O-ring seals.
11. If the fuel rail is not being replaced, go to the Installation Procedure.

Disassembly Procedure




1. Remove the fuel injector wire harness (2) from the fuel rail (1).
2. Remove the fuel injectors (4) from the fuel rail (4). Refer to Fuel Injector Replacement (Removal and Replacement).

Assembly Procedure




1. Install the fuel injector harness (2) to the fuel rail (1).
2. Install the fuel injectors (3) to the fuel rail. Refer to Fuel Injector Replacement (Removal and Replacement).

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 (1).

Caution: Refer to Fastener Caution (Fastener Caution).

4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel rail bolts (2).
Install the fuel rail attaching bolts (2) and tighten to 10 Nm (89 in. lbs.).
5. Install the fuel injector harness in-line connector (3) to the rocker cover.
6. Connect the fuel injector harness in-line connector (3) to the engine wire harness.




7. Connect the fuel feed pipe (3) to the fuel rail (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
8. Connect the fuel injector electrical connectors.
9. Install the intake manifold. Refer to Intake Manifold Replacement (Service and Repair).
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
11. Inspect for leaks.

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.