GM 12598329
Fuel Rail

The replacement process of fuel injector and fuel rail starts with releasing fuel system pressure by using ch 48027 or performing the operation without it when needed. The first step includes taking out both the upper Intake Manifold before handling the lower Intake Manifold. First disconnect the fuel injectors rail from the fuel feed pipe by removing its retaining clip. Crowd out debris from the fuel injector Intake Manifold entry points by blowing compressed air through that area. In order to avoid damaging injector electrical connector terminals and spray tips during fuel rail bolt removal properly support the fuel rail. Secure the fittings along with plugging all opened holes to prevent contamination entry. Separate the fuel rail from other components before discharging and disconnecting the fuel injector electrical connector. Remove the fuel injector retainer clip then detach the fuel injector while throwing away used fuel injector seals. When installing the fuel injector one should use fresh seals and place the fuel injector into position before attaching the retainer clip. The work is complete by reattaching the fuel injector electrical connector then using the lock to secure it. Seal the install of the fuel rail with its fuel injectors by tightening each fuel rail bolt to 10 n.m (89 lb in). You should connect the fuel feed pipe to the fuel rail while installing the retaining clip before reattaching the upper Intake Manifold.

Procedure to service and replace the fuel injectors requires the first step to be fuel system pressure relief. You must disconnect the upper and lower intake manifolds before you remove the retaining clip from the fuel pipe and separate the fuel feed from the Fuel Injector rail. A compressed air stream should blow away any debris inside the Intake Manifold entrance for the fuel injectors. You should carefully detach both Fuel Rail bolts and the Fuel Rail assembly but ensure your support maintains the injector electrical connector terminals and spray tips. After performing the hole plugging seal the fittings using caps. The procedure now includes unclipping the Fuel Injector electromechanical connection followed by disconnection and removal of the Fuel Injector while discarding the Fuel Injector seals. The installation process requires fresh Fuel Injector seals that should be installed after placing the Fuel Injector correctly and securing it with the retainer clip. After reconnecting the Fuel Injector electrical connector replace the lock security. The Fuel Rail assembly with fuel injectors should go in place before torquing the Fuel Rail bolts to 10 n.m (89 lb in). Last step before reinstalling the upper Intake Manifold is to join the fuel feed pipe to the Fuel Rail and install the fuel pipe retaining clip.

Lubricate the fuel injector cups with silicon-free engine oil GM P/N 12345610 (Canadian P/N 9931930) or equivalent.

Install the rebuilt direct fuel injectors into the cylinder heads and secure them with new hold down clamps.

Remove the fuel rail with the fuel injectors, disengage the fuel injector electrical connector lock, and disconnect the electrical connector. Then, remove the fuel injector retainer clip and the fuel injector itself, discarding the old fuel injector seals.

Install the front section of the charge air cooler front manifold assembly.

Install a new fuel rail crossover pipe and the high pressure fuel sensor, ensuring the electrical wiring is correctly routed to avoid damage.