Removal Procedure
Important: An eight digit identification number is located on the fuel
rail assembly. Refer to this model identification number if servicing or
part replacement is required.
- Relieve the fuel system pressure. Refer to
Fuel Pressure Relief
in engine controls.
- Before removal, clean the fuel rail assembly with a spray type
engine cleaner, GM X-30A or equivalent, if necessary. Follow the package
instructions. Do not soak fuel rails in liquid cleaning solvent.
- Remove the engine sight
shield bracket (1) nuts and bracket.
- Disconnect the generator
harness connector (1).
- Disconnect the (EVAP) canister purge valve harness connector (4).
- Disconnect the throttle position (TP) sensor harness connector
(2).
- Disconnect the electronic throttle control (ETC) harness connector
(3).
- Remove the upper engine wire harness bracket studs and position
the upper engine wire harness aside.
- Remove the Secondary Air Injection (AIR) crossover pipe if applicable,
Refer to
Secondary Air Injection Crossover Pipe/Hose Replacement
.
- Identify the connectors
to their corresponding injectors to ensure correct sequential injector firing
order after reassembly.
- Pull the top portion (2) of the injector connector up.
Do not pull the top portion of the connector past the top of the white portion (1).
- Push the tab (1)
on the lower side of the injector connector in order to release the connector
from the injector.
- Repeat step 12 and step 13 for each injector connector.
Notice:
• | Remove the fuel rail assembly carefully in order to prevent damage
to the injector electrical connector terminals and the injector spray tips.
Support the fuel rail after the fuel rail is removed in order to avoid damaging
the fuel rail components. |
• | Cap the fittings and plug the holes when servicing the fuel system
in order to prevent dirt and other contaminants from entering open pipes and
passages. |
- Disconnect the fuel feed and return pipes (1, 2) from the fuel
rail.
- Disconnect the fuel pressure
regulator vacuum line (1).
- Remove the fuel rail attaching
bolts (3).
- Remove the fuel rail assembly (1).
- Remove the injector lower
O-ring seal (4) from the spray tip end of each injector (3).
- Discard the O-ring seals.
Installation Procedure
- Lubricate the new lower
injector O-ring seals (4) with clean engine oil.
- Install the new O-ring seals (4) on the spray tip end of
each injector (3).
- Install the fuel rail
assembly (1) to the intake manifold.
- Apply a 5 mm (0.020 in) band of GM P/N 12345382
threadlock, or equivalent, to the threads of the fuel rail bolts.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the fuel rail attaching bolts (3).
Tighten
Tighten the bolts to 12 N·m (106 lb in).
- Connect the fuel pressure
regulator vacuum line (1).
- Connect the fuel feed
and return pipes (1, 2) to the fuel rail.
- Connect the injector electrical connectors (4).
• | Install each connector on the proper injector in order to ensure
correct sequential injector firing order. |
• | Rotate the injectors as required in order to avoid stretching
the wire harness. |
- Install the Secondary Air Injection (AIR) crossover pipe if applicable.
Refer to
Secondary Air Injection Crossover Pipe/Hose Replacement
.
- Install the upper engine
wire harness bracket .
- Install the retainer studs to the upper engine wire harness.
Tighten
Tighten the nut to 10 N·m (89 lb in)
- Reconnect the generator
harness connector (1).
- Reconnect the (EVAP) canister purge valve harness connector (4).
- Reconnect the throttle position (TP) sensor harness connector
(2).
- Reconnect the electronic throttle control (ETC) harness connector
(3).
- Install the engine sight
shield mounting bracket blots and nuts.
Tighten
Tighten the bolts to 10 N·m (89 lb in)
- Tighten the fuel filler cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Inspect for leaks using the following procedure:
19.1. | Turn ON the ignition, with the engine OFF, for 2 seconds. |
19.2. | Turn OFF the ignition for 10 seconds. |
19.3. | Turn ON the ignition, with the engine OFF. |
19.4. | Inspect for fuel leaks. |
- Install the engine sight shield.
Tighten
Tighten the bolts to 10 N·m (89 lb in).