GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Corvette 🢒 Engine 🢒 Engine Controls and Fuel - 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Fuel Injection Fuel Rail Assembly Replacement LS9

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the upper intake cover. Refer to Upper Intake Manifold Sight Shield Replacement.
  3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief
  4. Remove the front charge air cooler manifold. Refer to Charge Air Cooler Replacement

    5. Object Number: 2157866 Size: SH
  5. Disconnect the fuel injection Harness connectors (1, 4).
  6. Disconnect the MAP sensor harness connector (2).
  7. Disconnect the supercharger air output sensor harness connector (3).
  8. Disconnect the intake temperature sensor harness connector (5).
  9. Disconnect and place aside the PCV tube (6).

    10. Object Number: 2157868 Size: SH
  10. Disconnect all 8 ignition coil harness connectors (1).

    11. Object Number: 2157870 Size: SH
  11. Remove the front fuel rail fastener (1).
  12. Remove the fuel rail ball stud fasteners (2).
  13. Carefully disengage the fuel injectors (3) from the supercharger.
  14. Remove the fuel rail with the fuel injector harness (5) from the engine.

    15. Object Number: 2054131 Size: SH
  15. Remove the fuel injection wiring harness (2, 3) from the fuel rail (1) and fuel injectors.
  16. If replacing the fuel rail of an injector. Refer to Fuel Injector Replacement.

Installation Procedure
  1. Install the fuel injectors. Refer to Fuel Injector Replacement.

    2. Object Number: 2054131 Size: SH
  2. Install the fuel injection wiring harness ( 2, 3) to the fuel rail (1) and fuel injectors.

    3. Object Number: 2157870 Size: SH
  3. Install the fuel rail with the fuel injector harness (5) to the engine.
  4. Carefully locate the fuel injectors (3) into the supercharger. Install the left side first and then the right side.
  5. Apply threadlock to the ball stud and fastener threads. Refer to Adhesives, Fluids, Lubricants, and Sealers.

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

  6. Instal the ball studs (4) and the forward fastener (1) and tighten to 10 N·m (89 lb in).

    7. Object Number: 2157868 Size: SH
  7. Connect all 8 ignition coil harness connectors (1).

    8. Object Number: 2157866 Size: SH
  8. Connect the fuel injection Harness connectors (1, 4).
  9. Connect the MAP sensor harness connector (2).
  10. Connect the supercharger air output sensor harness connector (3).
  11. Connect the intake temperature sensor harness connector (5).
  12. Connect the PCV tube (6).
  13. Install the front charge air cooler manifold. Refer to Charge Air Cooler Replacement
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  15. Pressure the fuel system and check for fuel leaks.
  16. Install the upper intake cover. Refer to Upper Intake Manifold Sight Shield Replacement.

Fuel Injection Fuel Rail Assembly Replacement Without LS9


Object Number: 1969904 Size: MF

Callout

Component Name

Preliminary Procedures

  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the engine sight shield covers. Refer to Upper Intake Manifold Sight Shield Replacement.
  3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

1

Intake Manifold Bolt (Qty: 4)

Caution: Refer to Fastener Caution in the Preface section.

Procedure

Apply a 5 mm (0.20 in) band of GM P/N 12345382 (Canadian P/N 10953489) thread-lock or equivalent to the threads of the fuel rail and intake manifold bolts.

Tighten
10 N·m (89 lb in)

2

Stop Bracket (Qty: 2)

Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

3

Fuel Rail Bolt (Qty: 4)

Tighten
10 N·m (89 lb in)

4

Fuel Rail

Procedure

  1. Use the J 37088-A and separate the fuel line.
  2. Apply a small amount of lubricant at the injector O-rings to seal properly.

Special Tools

J 37088-A Fuel Line Disconnect Tool Set