GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Captiva Sport 🢒 Engine 🢒 Engine Controls and Fuel - 2.8L, 3.0L, 3.2L, or 3.6L 🢒 Fuel Injection Fuel Rail Assembly Replacement - Bank 1

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Remove the drive motor generator power inverter module. Refer to Drive Motor Generator Power Inverter Module Removal and Installation.
  3. Remove the fuel pipe shield. Refer to Fuel Pipe Shield Replacement.
  4. Remove the upper intake manifold. Refer to Upper 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 tube. Refer to Fuel Injection Fuel Rail Crossover Tube Replacement. Discard the pipe.
  7. Remove the foam insulator from the fuel rails.

    8. Object Number: 1977744 Size: SH
  8. Disconnect the fuel pressure sensor electrical connector and cut the wire harness tie straps.
  9. Remove the fuel rail (2) bolts (1).

    10. Object Number: 1977753 Size: SH
  10. Remove the fuel pressure sensor. Refer to Fuel Pressure Sensor Replacement
  11. Remove and discard the direct fuel injector hold down clamps.

    12. 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.

Installation Procedure

    Object Number: 1977754 Size: SH
  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. Object Number: 1977744 Size: SH
  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 first, then the 2 inner bolts, and hand tighten.

    6. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1977774 Size: SH
  6. Tighten the fuel rail bolts in the sequence shown:
    7. 6.1. Tighten the Bank 1 fuel rail bolts first pass to 12 N·m (106 lb in).
    6.2. Tighten the Bank 1 fuel rail bolts final pass to 23 N·m (17 lb ft).
  7. Install a NEW fuel rail crossover tube. 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. Object Number: 1977753 Size: SH

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

  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:
    12. 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 upper intake manifold. Refer to Upper 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 drive motor generator power inverter module. Refer to Drive Motor Generator Power Inverter Module Removal and Installation.