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Fuel Rail Assembly: Installation

  1. Lubricate the new lower injector "O" ring seals (4) with clean engine oil. See Figure.
  2. Install the new "O" ring seals (4) on the spray tip end of each injector (3).
  3. Install the fuel rail assembly.
    NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  4. Install the fuel rail attaching bolts. See Fig 3. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  5. Connect the fuel feed and return pipes (1, 2) to the fuel rail. See Fig 2. See FUEL LINE DISCONNECT FITTINGS (4.2L) .
  6. Connect the fuel injector electrical connectors.
  7. Connect the fuel pressure regulator vacuum line. See Fig 1.
  8. Install the intake manifold. See INTAKE MANIFOLD .
  9. Connect the negative battery cable.
  10. Inspect for leaks.
    • Turn ON the ignition, with the engine OFF for 2 seconds.
    • Turn OFF the ignition for 10 seconds.
    • Turn ON the ignition, with the engine OFF.
    • Inspect for fuel leaks.
Fig 1: Removing & Installing Fuel Rail Assembly (1 Of 3)
G00256509Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Fuel Rail Assembly (2 Of 3)
G00256510Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installing Fuel Rail Assembly (3 Of 3)
G00256511Courtesy of GENERAL MOTORS CORP.


  1. Lubricate the NEW lower injector "O" ring seals with clean engine oil. See Figure.
  2. Install the NEW "O" ring seals onto each injector, if necessary.
  3. Install the fuel rail. See Fig 4.
  4. Apply a 5 mm (0.020 in) band of threadlock GM P/N (12345382) to the threads of the fuel rail bolts.
  5. Install the fuel rail bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  6. Connect the fuel pressure regulator vacuum line.
  7. Connect the fuel feed and return pipes (1) to the fuel rail. See Fig 3. See FUEL LINE DISCONNECT FITTINGS (5.3L) .
  8. Position the upper engine wire harness over the engine.
  9. Install the upper engine wire harness retainer nut (1). See Figure. Tighten the nut to specification. See TORQUE SPECIFICATIONS .
  10. Install the PCV hose (with valve). See Figure.
  11. Connect the following electrical connectors on the left hand side of the engine:
    • EVAP purge solenoid (1). See Figure.
    • Knock sensor (2).
    • MAP sensor (3).
    • Main coil (5).
    • Fuel injectors (4).
  12. Perform the following steps in order to Connect the fuel injector electrical connectors.
    • Install the connectors to their corresponding injectors to ensure correct reassembly.
    • Connect the fuel injector electrical connector.
    • Push the CPA retainer (2) on the connector in 1 click. See Figure.
    • Repeat the steps for each injector electrical connector.
  13. Install the electrical harness to the clips on ignition coil bracket.
  14. Connect the following electrical connectors on the right hand side of the engine:
    • Coil main electrical harness (1). See Figure.
    • ETC (2).
    • Fuel injectors (3).
  15. Install the electrical harness to the clips on ignition coil bracket.
  16. Connect the generator electrical connector.
  17. Connect the MAF/IAT sensor electrical connector (1). See Figure.
  18. Install the wire harness to the clip (1) on the cylinder head. See Fig 2.
  19. Connect the A/C compressor pressure switch electrical connector (2).
  20. Install the air cleaner outlet duct. See AIR CLEANER RESONATOR OUTLET DUCT .
  21. Install the fuel fill cap.
  22. Connect the negative battery cable.
  23. Use the following procedure in order to inspect for leaks:
    • Turn the ignition ON, with the engine OFF, for 2 seconds.
    • Turn the ignition OFF for 10 seconds.
    • Turn the ignition ON, with the engine OFF.
    • Inspect for fuel leaks.
Fig 1: Removing & Installing Fuel Rail Assembly (1 Of 4)
G00256514Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing & Installing Fuel Rail Assembly (2 Of 4)
G00256515Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing & Installing Fuel Rail Assembly (3 Of 4)
G00256512Courtesy of GENERAL MOTORS CORP.
Fig 4: Removing & Installing Fuel Rail Assembly (4 Of 4)
G00256513Courtesy of GENERAL MOTORS CORP.
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