Fuel Rail Assembly Replacement

FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE




1. Remove the air cleaner outlet duct.

IMPORTANT: An eight-digit identification number (1) is located on the fuel rail. Refer to this model identification number if servicing or part replacement is required.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.




3. Disconnect the air conditioning (NC) compressor pressure switch electrical connector (2).
4. Remove the wire harness from the clip (1) on the cylinder head.




5. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector (1).




6. Disconnect the generator electrical connector.




7. Disconnect the following electrical connectors on the right hand side of the engine:
- Coil main electrical harness (1)
- Electronic throttle control (ETC) (2)
- Fuel injectors (3)




8. Perform the following steps in order to disconnect the fuel injector electrical connectors.
8.1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
8.2. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click.
8.3. Push the tab (1) on the connector in.
8.4. Disconnect the fuel injector electrical connector.
8.5. Repeat the steps for each injector electrical connector.
9. Remove the electrical harness from the clips on ignition coil bracket.




10. Disconnect the following electrical connectors on the left hand side of the engine:
- Evaporative emission (EVAP) purge solenoid (1)
- knock sensor (2)
- Manifold absolute pressure (MAP) sensor (3)
- Main coil (5)
- Fuel injectors (4).
11. Remove the electrical harness from the clips on ignition coil bracket.




12. Remove the positive crankcase ventilation (PCV) hose (with valve).




13. Remove the upper engine wire harness retainer nut (1).
14. Reposition the upper engine wire harness aside.




15. Disconnect the fuel feed and return pipes (1) from the fuel rail.
16. Disconnect the fuel pressure regulator vacuum line.




17. Remove the fuel rail bolts.

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.

IMPORTANT: Before removal, clean the fuel rail 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.

18. Remove the fuel rail.




19. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
20. Discard the O-ring seals.

INSTALLATION PROCEDURE




1. Lubricate the NEW lower injector O-ring seals (4) with clean engine oil.
2. Install the NEW O-ring seals (4) onto each injector, if necessary.




3. Install the fuel rail.
4. Apply a 5 mm (0.020 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel rail bolts.

NOTE: Refer to 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) to the fuel rail.




8. Position the upper engine wire harness over the engine.
9. Install the upper engine wire harness retainer nut (1).

Tighten
Tighten the nut to 5 N.m (44 lb in).




10. Install the PCV hose (with valve).




11. Connect the following electrical connectors on the left hand side of the engine:
- EVAP purge solenoid (1)
- Knock sensor (2)
- MAP sensor (3)
- Main coil (5)
- Fuel injectors (4)




12. Perform the following steps in order to Connect the fuel injector electrical connectors.
12.1. Install the connectors to their corresponding injectors to ensure correct reassembly.
12.2. Connect the fuel injector electrical connector.
12.3. Push the CPA retainer (2) on the connector in 1 click.
12.4. Repeat the steps for each injector electrical connector.
13. Install the electrical harness to the clips on ignition coil bracket.




14. Connect the following electrical connectors on the right hand side of the engine:
- Coil main electrical harness (1)
- ETC (2)
- Fuel injectors (3)
15. Install the electrical harness to the clips on ignition coil bracket.




16. Connect the generator electrical connector.




17. Connect the MAF/IAT sensor electrical connector (1).




18. Install the wire harness to the clip (1) on the cylinder head.
19. Connect the A/C compressor pressure switch electrical connector (2).
20. Install the air cleaner outlet duct.
21. Install the fuel fill cap.
22. Connect the negative battery cable.
23. Use the following procedure in order to inspect for leaks:
23.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
23.2. Turn the ignition OFF for 10 seconds.
23.3. Turn the ignition ON, with the engine OFF.
23.4. Inspect for fuel leaks.