GM 24508941
Fuel Rail

The first step to replace a Fuel Rail assembly requires users to drain fuel pressure then cover the fittings and maintain hole plugs to stop contamination. The next step requires cleaning the Fuel Rail assembly before disconnecting the fuel feed pipes and return pipes from the Fuel Rail tubes and the vacuum line from the Fuel Pressure Regulator. The coil wires require removal after depressing the lock tab and removing electrical connectors from fuel injectors. The Fuel Injector remover (J 43013) should be used to elevate the injectors at a controlled speed after you disconnect the Fuel Rail hold-down bolts before removing the Fuel Rail while applying equal force throughout both rail sides. Install the Fuel Rail assembly to the Intake Manifold but first add clean motor oil to the o-rings of all serviced components. Feed the fuel rails into position by hand. Use the provided implements to complete the reinstall by attaching Fuel Rail hold-down bolts to 10 n.m (89 lb in) then joining the Fuel Injector electrical connectors to the fuel feed and return pipes and a vacuum line to the Fuel Pressure Regulator. Install new ignition coil wires before tightening the fuel fill cap while hooking the negative Battery Cable. The inspection for leaks requires turning the ignition on for 2 seconds followed by turning it off for 10 seconds and finally turning it on to check for fuel leaks. The installation sequence includes the last step which is attaching the fuel injection sight shield.

The Fuel Injector removal tool (J 43013) replaces the Fuel Rail assembly while implementing hole-plugging and joining fitting-cap procedures to keep fuel contamination away from the system. Release the system pressure from the fuel supply and clean both the Fuel Rail unit and its connections. You must disconnect the fuel feed pipes and fuel return pipes from Fuel Rail tubes alongside the vacuum line from the Fuel Pressure Regulator and ignition coil wires and six injector electrical connectors. The Fuel Injector removal tool (J 43013) helps you raise the injectors carefully before removing the Fuel Rail with balanced force applied to both sides. Place the Fuel Rail assembly on the Intake Manifold by inserting fuel injectors manually after replacing o-rings on all parts and applying clean motor oil to them. Fitting the Fuel Rail hold-down bolts requires a torque setting of 10 n.m (89 lb ft). Connect the six Fuel Injector electrical connectors followed by reattachment of the fuel feed and return pipes to their corresponding tubes on the Fuel Rail and that of the vacuum line to the pressure regulator. At the end, install ignition coil wires before tightening the fuel fill cap while connecting the negative Battery Cable. Before installing the fuel injection sight shield, use the ignition switchron, offfor 10 seconds, off, onto detect any fuel leaks.

The Fuel Rail assembly requires protected fuel passages which demands fitting caps and hole plugs during servicing and clean fuel system component handling. The first step requires the user to drain pressure from the fuel system. Begin by cleaning all connections on the Fuel Rail assembly before proceeding to remove the fuel feed and return pipes from the Fuel Rail tubes before taking off the vacuum line from the Fuel Pressure Regulator. The proper order for removing the Fuel Rail is first disconnect wires from the ignition coils along with the 6 injector electrical connectors after which the technician can remove the Fuel Rail hold-down bolts. Relaxation of pressure in the fuel system must occur before gently dismounting the Fuel Rail while applying equal force to both its sides. The installation procedure includes replacing all serviced components o-rings before applying clean motor oil to fuel injector o-rings and then carefully placing the Fuel Rail assembly onto the Intake Manifold while seating each fuel injector manually. Secure the Fuel Rail hold-down bolts by torquing them to 10 n.m (89 lb in). Connect the vacuum line to the Fuel Pressure Regulator and the ignition coil wires to their respective places while also securing the 6 fuel injector electrical connectors and the fuel feed and return pipes to the Fuel Rail tubes. Begin by tightening the fuel fill cap followed by Battery Cable reconnection after which you should inspect for leaks using a two-second ignition on then ten-second ignition off before applying power again to check for fuel leakage. The last installation task entails fitting the fuel injection sight shield.

Remove the ignition coil wires.

Replace the O-rings on all components, lightly oil the fuel injector O-rings with clean motor oil, and place the fuel rail assembly on the intake manifold, seating the fuel injectors by hand.

Lightly oil the fuel injector O-rings with clean motor oil, ensuring to replace the O-rings on all serviced components.

Clean the fuel rail assembly and connections.

Reattach the fuel injector electrical harness clips, connect the fuel injector electrical connectors, and install the bypass valve actuator.

It is recommended that the fittings be capped and the holes plugged to prevent dirt and contaminants from entering the fuel passages.

Turn on the ignition for 2 seconds, off for 10 seconds, then on again, checking for fuel leaks.

Discard the fuel feed pipe and fuel return pipe O-rings.

Turn the ignition ON for 2 seconds, OFF for 10 seconds, and then ON again, checking for fuel leaks.

By capping the fittings and plugging the holes.

Ensure the fuel injector O-rings are installed correctly, with the black O-ring in the upper position and the brown O-ring in the lower position.