GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 1683133  Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .

  4. Object Number: 1578460  Size: SH
  5. Disconnect the electronic throttle control (ETC) electrical connector.
  6. Remove the 2 engine harness clips from the fuel rail tabs.

  7. Object Number: 1571760  Size: SH
  8. Remove the fuel injector wiring harness electrical connector (1) clip from the intake manifold tab.
  9. Disconnect the engine harness electrical connector (2) from the fuel injector harness wiring electrical connector (1).

  10. Object Number: 1578472  Size: SH
  11. Remove the fuel rail bolts.
  12. Important: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector spray tips.

  13. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.
  14. Remove the fuel rail.

  15. Object Number: 1336272  Size: SH

    Important: The fuel injector tip insulators may be located on the injector or may still be located in the cylinder head. Either way, ensure that all 4 injector tip insulators are removed and discarded.

  16. Remove and discard the fuel injector tip insulators.

  17. Object Number: 1683401  Size: SH
  18. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  19. Remove the fuel injector wiring harness clips from the fuel rail.
  20. Remove the fuel injector wiring harness from the fuel rail.
  21. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement .

Installation Procedure

Important: Install only NEW lower O-rings if the fuel rail and injectors were removed and re-installed. If the fuel rail was replaced, then install NEW upper and lower O-rings.


    Object Number: 1683401  Size: SH
  1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
  2. Install the fuel injector wiring harness clips to the fuel rail.
  3. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.

  4. Object Number: 1336272  Size: SH
  5. Lubricate the NEW fuel injector tip insulators with clean engine oil.
  6. Install the NEW fuel injector tip insulators to the cylinder head.

  7. Object Number: 1578472  Size: SH
  8. Lubricate the fuel injector O-rings with clean engine oil.
  9. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  10. Notice: Refer to Fastener Notice in the Preface section.

  11. Carefully push down on the fuel rail in order to insert the injectors into the cylinder head ports.
  12. Install the fuel rail bolts.
  13. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1571760  Size: SH
  14. Connect the engine harness electrical connector (2) to the fuel injector wiring harness electrical connector (1).
  15. Install the fuel injector wiring harness electrical connector (1) clip to the intake manifold tab.

  16. Object Number: 1578460  Size: SH
  17. Install the 2 engine harness clips to the fuel rail tabs.
  18. Connect the ETC electrical connector.

  19. Object Number: 1683133  Size: SH
  20. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  21. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement .
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  23. Inspect for fuel leaks using the following procedure:
  24. 17.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    17.2. Turn OFF the ignition for 10 seconds.
    17.3. Turn ON the ignition.
    17.4. Inspect for fuel leaks.