GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.


Object Number: 12745  Size: SH
  1. Relieve fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the upper intake manifold. Refer to Upper Intake Manifold .
  3. Remove the fuel feed and return pipes from the fuel rail tubes by squeezing tabs and pulling the lines apart.
  4. Remove the main injector harness electrical connector.
  5. Remove the fuel pressure regulator vacuum line.
  6. Remove the fuel rail retaining bolts.
  7. Remove the fuel rail assembly.
  8. Remove the Injector O-ring seal from spray tip end of each injector. Discard seals. With the O-ring removed the O-ring backup may slip off of the injector. Be sure to retain the O-ring backup for reuse.

Installation Procedure


Object Number: 12745  Size: SH
  1. Ensure that O-ring backups are on injectors before installing new O-rings. Lubricate new injector O-ring seals with clean engine oil and install on spray tip end of each injector.
  2. Install the fuel rail assembly in intake manifold. Tilt rail assembly to install injectors.
  3. Install the fuel rail attaching bolts.
  4. Tighten
    Tighten fuel rail attaching bolt to 10 N·m(89 lb. in.).

  5. Install the fuel pressure regulator vacuum line.
  6. Install the main injector harness electrical connector.
  7. Install the fuel feed and return pipes to the fuel rail tubes.
  8. Install the upper intake manifold. Refer to Upper Intake Manifold .
  9. Install the fuel filler cap.

Notice: 

   • Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
   • Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
   • Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.