Fuel Rail Assembly Replacement
REMOVAL PROCEDUREIMPORTANT:
^ The L59 E85 fuel rail is comprised of a material that is compatible with fuel that has a concentration of up to 85 percent Ethanol. The E85 fuel rail also uses an E85 Denso fuel injectors. Because of this, special procedures will be used in servicing the fuel rail and associated components. The screws that fasten the retaining clips for the crossover pipe to the fuel rails are thread cutting and therefore should NOT be removed from the fuel rail. The fuel rail will be serviced as an entire component.
^ An eight-digit identification number (1) is located on the fuel rail. Refer to this model identification number if service or part replacement is required.
1. Remove the engine sight shield.
2. Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvents.
3. Disconnect the accelerator control and cruise control cables from the cable bracket, if equipped.
4. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever, if equipped.
5. Disconnect the accelerator control cable from the throttle lever, if equipped.
6. Remove the upper engine wire harness retainer nut.
7. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector.
8. Reposition the upper engine wire harness aside.
9. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
10. Mark the electrical connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
IMPORTANT: When disconnecting the Multec (R) 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable.
11. Pull the connector position assurance (CPA) (2) on the injector connector up.
12. Push the tab (1) on the injector connector in.
13. While pushing the tab (1) on the injector connector in, release the CPA (2).
14. Disconnect the fuel injector connector electrical connector.
15. Repeat the steps for each injector connector.
NOTE:
^ 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.
16. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
17. Disconnect the fuel pressure regulator vacuum line.
18. Remove the fuel rail bolts.
19. Remove the fuel rail.
IMPORTANT: The Denso fuel injectors installed on the E85 application will NOT have O-rings and retaining clips serviced separately. Therefore the fuel injectors will be replaced whenever an O-ring or clip needs to be replaced.
20. Inspect the fuel injector lower O-ring seals (5) of each fuel injector (3 ) for damage.
21. Replace the fuel injectors as needed.
INSTALLATION PROCEDURE
1. Install NEW fuel injectors (3), if required.
2. Lubricate the lower fuel injector O-ring seals (4) with clear engine oil.
3. Install the fuel rail.
4. Apply a 5 mm (0.020 in) band of GM P/N 12345382 threadlock, or equivalent, to the threads of the fuel rail bolts.
NOTE: Refer to the Fastener Notice in Service Precautions.
5. Install the fuel rail bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
6. Connect the fuel pressure regulator vacuum line.
7. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
8. Connect the fuel injector electrical connectors.
^ Install each connector onto the correct fuel injector in order to ensure correct sequential injector firing order.
^ Rotate the fuel injectors as required in order to avoid stretching the wire harness.
9. Position the upper engine wire harness in place.
10. Connect the EVAP purge solenoid electrical connector.
11. Install the retainer nut to the upper engine wire harness.
Tighten
Tighten the nut to 5.5 N.m (49 lb in).
12. Connect the accelerator control and cruise control cables to the cable bracket, if equipped.
13. Connect the accelerator control cable to the throttle lever, if equipped.
14. Connect the cruise control cable engine-end fitting to the stud on the throttle lever, if equipped
15. Use the following procedure in order to inspect for leaks:
15.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
15.2. Turn OFF the ignition for 10 seconds.
15.3. Turn ON the ignition, with the engine OFF.
15.4. Inspect for fuel leaks.
16. Install the engine sight shield.