OEM 2003 GMC Savana 3500 Fuel Rail

2003 GMC Savana 3500 Fuel Rail Parts Questions & Experts Answers

• Q: How to replace the fuel rail assembly on 2003 GMC Savana 3500?

  A: The Fuel Rail assembly replacement starts by taking out the engine cover together with the air cleaner resonator outlet duct. The Fuel Rail assembly needs cleaning through spray application of gm x-30a engine cleaner without submerging it in cleaning solvents. A serviceable Fuel Rail assembly requires an eight-digit code for identification which is found on its assembly. Disconnect the accelerator control cable and cruise control cable from their cables bracket and from the Throttle Body in case it has them attached. The technician should first remove the upper retainer nut of the engine wire harness and disconnect the evap purge valve connector to relocate the harness to a separate position. Before reassembly it is necessary to mark the electrical connectors for their specific injectors in order to maintain correct firing order. During this step it is vital to relieve fuel system pressure. Avoid pliers when disconnecting the multec 2 fuel injector connectors as the device can cause connector damage. To disconnect a fuel injector plug properly, pull the connector position assurance (CPA) up on the connector and push the tab of the connector while releasing the cpa. Each pipe connecting to the Fuel Rail needs to be separated before disconnecting the fuel feed and return pipes from the Fuel Rail. Disconnect the fuel pressure regulator vacuum line first and loosen the retainer screw securing the crossover tube to the right Fuel Rail. After removing the Fuel Rail bolts, remove the Fuel Rail itself. Remove the lower o-ring seals from the injectors after discarding them. Installation requires engine oil lubrication of new fuel injector lower o-ring seals prior to inserting them onto each injector. Release the retaining clip attaching screw for the crossover pipe retainer located on the right-hand Fuel Rail of the vehicle so you can remove the crossover pipe rail combined with its o-ring. Prepare a clean engine oil to lubricate the new o-ring and place it on the crossover pipe before inserting the crossover pipe into the right Fuel Rail. Attach the retaining clip attaching screw to its threads by hand before installing the crossover pipe retainer and screw loosely and then the Fuel Rail. Use gm p/n 12345382 threadlock with a 5 mm width to secure the Fuel Rail bolts before installation at 10 n.m torque and fasten the screw to 3.8 n.m where you should reconnect the fuel pressure regulator vacuum line together with fuel feed and return pipes to the Fuel Rail. Connect the fuel injector electrical connectors in their proper sequence then rotate the injector units if necessary to prevent wire harness stretching. The upper engine wire harness must be positioned correctly before connecting the evap purge solenoid and installing the retainer nut to 5.5 n.m torque. Then, connect the accelerator control cable and cruise control cable followed by installing the air cleaner resonator outlet duct and engine cover. The inspection process for fuel leaks demands that you activate the ignition system with the engine shut down for two seconds followed by engine shutoff for ten seconds before another activation to scrutinize fuel leakage.