GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 664853  Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cables from both batteries.
  2. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove air cleaner layer. Refer to Air Cleaner Replacement
  4. Remove the upper radiator hose and two hose clamps.
  5. Important: Tape the turbo to keep foreign material out.

  6. Remove the turbo charged air outlet hose.

  7. Object Number: 786978  Size: SH
  8. Disconnect the 3 glow plug relay connectors (1, 2, 3).
  9. Remove the glow plug bracket.

  10. Object Number: 674653  Size: SH
  11. Disconnect both 40 pin and 24 pin engine connectors.
  12. Remove the engine connector bracket and set aside.
  13. Disconnect the fuel in-line and return lines.
  14. Remove the L-bracket holding the fuel lines.

  15. Object Number: 687021  Size: SH
  16. Remove the positive crankcase ventilation (PCV) hose and clamp and move out of the way.
  17. Remove the water pipe outlet from the thermostat housing.
  18. Remove the serpentine belt.

  19. Object Number: 652573  Size: SH
  20. Remove the bolts holding the air conditioning compressor and flip the unit aside.

  21. Object Number: 660448  Size: SH
  22. Remove the line from the junction block to the injection pump.

  23. Object Number: 660446  Size: SH
  24. Loosen the high pressure line (1) at the back end of the fuel rail and remove.

  25. Object Number: 660449  Size: SH
  26. Remove the junction block assembly.

  27. Object Number: 660451  Size: SH
  28. Loosen the high pressure injection lines at the four injectors first.
  29. Loosen the high pressure injection lines at the four fittings on the fuel rail.
  30. Mark the high pressure injection lines in order and remove them.

  31. Object Number: 660456  Size: SH
  32. Remove the three bolts holding the fuel rail and remove.

Installation Procedure


    Object Number: 660456  Size: SH
  1. Install the new fuel rail and bolts.

  2. Object Number: 660451  Size: SH

    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.

  3. Connect the high pressure lines between the fuel rail and injectors.
  4. Tighten
    Tighten the high pressure lines to 44 N·m (32 lb ft).


    Object Number: 660449  Size: SH
  5. Install the junction block assembly.

  6. Object Number: 660446  Size: SH
  7. Connect the high pressure line to the back end of the fuel rail.
  8. Tighten
    Tighten the fuel rail bolts to 26 N·m (19 lb ft).


    Object Number: 660448  Size: SH
  9. Install the line from the junction block to the injection pump.

  10. Object Number: 652573  Size: SH
  11. Install the bolts holding the air conditioning compressor.
  12. Install drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
  13. Install the water outlet pipe to thermostat housing.

  14. Object Number: 687021  Size: SH
  15. Attach the PCV hose and clamp.
  16. Install the L-bracket holding the fuel lines.
  17. Connect the fuel lines.
  18. Install the glow plug bracket.
  19. Install the glow plug relay. Refer to Glow Plug Relay Replacement .

  20. Object Number: 786978  Size: SH
  21. Connect the connectors to the glow plug relays (1, 2, 3).

  22. Object Number: 664853  Size: SH
  23. Attach the turbo hose and clamp at the turbo to the intercooler.
  24. Replace the upper radiator hose and two hose clamps.
  25. Replace the coolant. Refer to Auxiliary Generator Replacement in Engine Electrical.
  26. Connect the negative battery cables to both batteries.
  27. Replace all hold down ties.
  28. Check for fuel leaks or noises. Refer to Fuel System Diagnosis
  29. Install air cleaner layer. Refer to Air Cleaner Replacement
  30. After the engine warms up, refill the coolant reservoir to the proper level.