GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Uplander Ext. 🢒 Engine 🢒 Engine Controls and Fuel - 3.9L 🢒 Fuel Injector and Fuel Rail Replacement

Removal Procedure
  1. An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.

    2. Warning: 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.

    Caution: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

    Note: If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.


    Object Number: 1557674 Size: SH
  2. Disconnect the fuel feed pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  3. Disconnect any remaining electrical connectors.
  4. Remove the upper intake manifold. Refer to Upper Intake Manifold Replacement .
  5. Remove the fuel injector harness connector bracket bolt from the intake manifold.
  6. Disconnect the camshaft position (CMP) sensor electrical connector.
  7. Remove the fuel rail bolts.
  8. Remove the fuel rail (1).
  9. Remove and discard the O-rings from the spray tip end of each injector.

    10. Object Number: 537311 Size: SH

    Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

  10. Remove the fuel injector retaining clip (1), if required.
  11. Remove the fuel injector (3) from the fuel rail, if required.
  12. Remove and discard the fuel injector upper O-ring (2).

Installation Procedure

    Object Number: 537308 Size: SH

    Note: DO NOT reuse the fuel injector O-ring seals. Install NEW O-ring seals during assembly.

    Note: Ensure to use the correct part number when ordering the replacement fuel injectors.

  1. The fuel injector (1) is stamped with a part number identification (2).

    2. Object Number: 537311 Size: SH
  2. Lubricate the NEW injector O-rings (2) with clean engine oil.
  3. Install the NEW fuel injector upper O-ring (2).
  4. Install the fuel injector (3) to the fuel rail, if required.
  5. Install the fuel injector retaining clip (1), if required.

    6. Object Number: 1557674 Size: SH

    Caution: 

       • 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.

  6. Lubricate the NEW lower injector O-rings with clean engine oil.
  7. Install the fuel rail assembly (1) into the intake manifold. Tilt the fuel rail assembly slightly to install the injectors.

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

  8. Install the fuel rail bolts and tighten to 10 N·m (89 lb in) .
  9. Connect the CMP sensor electrical connector.
  10. Position the fuel injector harness connector bracket to the intake manifold.
  11. Install the fuel injector harness connector bracket bolt and tighten to 8 N·m (71 lb in) .
  12. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
  13. Connect any remaining electrical connectors.
  14. Connect the fuel feed pipe to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  15. Inspect for fuel leaks with the following procedure:
    16. 15.1. Turn ON the ignition for 2 seconds.
    15.2. Turn OFF the ignition for 10 seconds.
    15.3. Turn ON the ignition.
    15.4. Inspect for fuel leaks.