Fuel Rail: Service and Repair

Fuel Rail Assembly Replacement

Removal Procedure

Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Remove the air cleaner outlet duct.
3. Disconnect the following electrical connectors:

* EVAP purge solenoid (1)
* Manifold absolute pressure (MAP) sensor (2)
* Electronic throttle control (ETC) (3)
* Oil pressure sensor (4)
* Valve lifter oil manifold (5)




4. Disconnect the generator electrical connector (2).




5. Remove the connector position assurance (CPA) retainer (3).
6. Disconnect the main ignition coil harness electrical connector (4).

Important: Mark the injector connectors to their corresponding injectors to ensure correct reassembly.

7. Disconnect the fuel injector electrical connectors (1, 2).




8. Remove the CPA retainer (3).
9. Disconnect the main ignition coil harness electrical connector (1).

Important: Mark the injector connectors to their corresponding injectors to ensure correct reassembly.

10. Disconnect the fuel injector electrical connectors (2, 4).




11. Remove the engine wiring harness retainers from the tabs on the fuel rail. Reposition the harness out of the way.




12. Disconnect the fuel feed (1) and EVAP (2) lines.




13. Note the location of the fuel rail ground strap (557).




14. Remove the intake manifold bolt (512) and ground strap (557).
15. Remove the fuel rail bolts (511).
16. Remove the fuel rail (510) with injectors. Lift evenly on both sides of the fuel rail until all injectors have been removed from their bores.

Important: Do not separate the fuel injectors from the fuel rail unless component service is required.

17. If replacing the fuel rail, remove the fuel injectors.

Installation Procedure

Important: Do not reuse the fuel injector O-ring seals. Install NEW O-ring seals during assembly.




1. Note the installed location of the fuel rail ground strap (557).




2. If replacing the fuel rail, install the fuel injectors.
3. If necessary, Lubricate the NEW O-ring seals with clean engine oil.
4. If necessary, install NEW O-ring seals to the fuel injectors.
5. Install the fuel rail (510) with injectors. Push firmly on both sides of the rail until all the injectors have been seated into their bores.
6. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the fuel rail bolts.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the fuel rail bolts (511).

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

8. Install the ground strap (557) and intake manifold bolt (512).

Tighten the bolt to 10 N.m (89 lb in).




9. Connect the fuel feed (1) and EVAP (2) lines.




10. Position the harness to the engine. Install the engine wiring harness retainers to the tabs on the fuel rail.






Important: Install the marked injector connectors to their corresponding injectors.

11. Connect the fuel injector electrical connectors (2, 4).
12. Connect the main ignition coil harness electrical connector (1).
13. Install the CPA retainer (3).






Important: Install the marked injector connectors to their corresponding injectors.

14. Connect the fuel injector electrical connectors (1, 2).
15. Connect the main ignition coil harness electrical connector (4).
16. Install the CPA retainer (3).




17. Connect the generator electrical connector (2).




18. Connect the following electrical connectors:

* EVAP purge solenoid (1)
* MAP sensor (2)
* ETC (3)
* Oil pressure sensor (4)
* Valve lifter oil manifold (5)

19. Install the air cleaner outlet duct.
20. Connect the negative battery cable.
21. Use the following steps to inspect for leaks:

1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON with the engine OFF.
4. Inspect for leaks.

22. Install the engine sight shield.