GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Captiva 🢒 Diagnostic Navigation 🢒 Vehicle Diagnostic Information 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure


    Object Number: 1795481 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.

    2. Warning: Refer to Relieving Fuel Pressure Warning in the Preface section.

  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  3. Remove the upper intake manifold assembly. Refer to Upper Intake Manifold Replacement.
  4. Disconnect the fuel feed line from the fuel rail.

    5. Clean around the area where the fuel injectors enter the lower intake manifold.


    Object Number: 1803606 Size: SH
  5. Remove the bolt (1), three places, attaching the fuel rail to the lower intake manifold.

    6. 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. Slide the fuel injector wiring connector locking tab upwards in the direction of the arrow.
  7. Disconnect the connector from the fuel injector.

    8. Object Number: 1803607 Size: SH
  8. Slide the fuel injector wiring connector locking tab (1) upwards in the direction of the arrow.
  9. Disconnect the connector from the fuel injector.

    10. Object Number: 1803608 Size: SH
  10. Using a flat-blade screwdriver, remove the fuel injector retaining clip (1) from the fuel injector (2).

    11. Discard the retaining clip.


    Object Number: 1803609 Size: SH
  11. Remove the fuel injector (1) from the fuel rail.
  12. Remove and discard the fuel injector seals (2).

Installation Procedure


    Object Number: 1803608 Size: SH
  1. Install new fuel injector seals and lubricate with clean engine oil.
  2. Install the fuel injector (2) to the fuel rail.
  3. Install a new fuel injector retaining clip (1).
  4. Connect the fuel injector connector.

    5. Object Number: 1803606 Size: SH
  5. Carefully install the fuel rail and injector assembly.

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

    Note: Ensure the fuel injectors are correctly seated in the lower intake manifold, and the fuel rail attaching brackets are correctly located prior to tightening the attaching bolts.

  6. Install the fuel rail assembly attaching bolts (1) snd tighten to 10 N·m (89 lb in).
  7. Connect the fuel feed hose to the fuel rail.
  8. Inspect the fuel rail and quick connect fitting for leaks.
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.