Fuel Injection Fuel Rail Assembly Replacement - Bank 1 LLT

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement.
3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement.
4. Remove the intake manifold. Refer to Intake Manifold Replacement.
5. Remove the high pressure fuel pipe. Discard the pipe. Refer to Fuel Feed Intermediate Pipe Replacement.
6. Remove the fuel rail crossover pipe. Refer to Fuel Injection Fuel Rail Crossover Tube Replacement. Discard the pipe.
7. Remove the foam insulator from the fuel rails.



8. Disconnect the fuel pressure sensor electrical connector and cut the wire harness tie straps.
9. Remove the fuel rail (1) bolts (2).




Caution: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring.

10. Remove the fuel pressure sensor. Refer to Fuel Pressure Sensor Replacement.
11. Remove and discard the direct fuel injector hold down clamps.

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

12. Once the fuel rail is removed, remove the fuel injectors and rebuild them. Refer to Fuel Injector Replacement.

1. Install the rebuilt direct fuel injectors (1) to the cylinder heads. Refer to Fuel Injector Replacement.
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 (1) 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 first, then the 2 inner bolts, and hand tighten.

Caution: Refer to Fastener Caution in the Preface section.




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

Tighten

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.
8. Install a NEW high pressure fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement.
9. Install the high pressure fuel sensor (1). Refer to Fuel Pressure Sensor Replacement.



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:

11.1.

Turn ON the ignition, with the engine OFF for 2 seconds.

11.2.

Turn OFF the ignition, for 10 seconds.

11.3.

Turn ON the ignition, with the engine OFF.

11.4.

Inspect for fuel leaks.

12. Install the foam insulator from the fuel rails.
13. Install the intake manifold. Refer to Intake Manifold Replacement.
14. Install the fuel pipe shield. Refer to Fuel Pipe Shield Replacement.
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.