Fuel Rail: Service and Repair

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE




1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Remove the fuel injector sight shield.

NOTE:
- Carefully remove the fuel rail assembly 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.
- Prevent dirt and other contaminants from entering the open pipes and passages. Cap the fittings and plug the holes when servicing the fuel system.

3. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
4. 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 the fuel rail in liquid cleaning solvent.




5. Remove the engine compartment fuel line (3).
6. Disconnect the engine compartment evaporative emission (EVAP) line (1) from the chassis EVAP line.
7. Disconnect the engine compartment EVAP line from the purge valve..
8. Remove the EVAP line from the vehicle.




9. Disconnect the fuel injector electrical connectors. Identify the connectors to their corresponding injectors in order to ensure the correct sequential injector firing order after reassembly.
10. Remove the fuel injector wiring harness retainers from the fuel rail.




11. Note the location of the fuel rail ground strap (1) on the intake manifold. The fuel rail ground strap must be installed during assembly.




12. Remove the fuel rail attaching bolts.
13. Remove the fuel rail assembly.
14. Remove the fuel injectors, if necessary.
15. Remove the injector lower O-ring seal from the spray tip end of each injector.
16. Discard the lower O-ring seals.

INSTALLATION PROCEDURE




1. If previously removed, install the fuel injectors.
2. Note the location of the fuel rail ground strap (1) on the intake manifold. The fuel rail ground strap must be installed during assembly.




3. Lubricate the new lower injector O-ring seals with clean engine oil.
4. Install the new O-ring seals on the spray tip end of each injector.
5. Install the fuel rail assembly to the intake manifold.

CAUTION: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

6. Apply a 5 mm (0.02 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock or equivalent to the threads of the fuel rail bolts.
7. Install the fuel rail attaching bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the fuel rail attaching bolts to 10 N.m (89 lb in).




8. Install the fuel injector wire harness retainers to the fuel rail.
9. Connect the injector electrical connectors.
- Install each connector on the proper injector in order to ensure the correct sequential injector firing order.
- Rotate the injectors as required in order to avoid stretching the injector wiring harness.




10. Install the EVAP line to the vehicle.
11. Connect the EVAP line to the EVAP valve.
12. Connect the EVAP line to the chassis EVAP line (1).
13. Install the engine compartment fuel pipe (3).




14. Connect the negative battery cable.
15. Perform the following procedure in order to inspect for leaks:
1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Inspect for fuel leaks.
16. Install the fuel injector sight shield.