CTS 2006-2007, CTS-V 2005-2007, DTS 2006-2007

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.8L & 3.6L Engines

WARNING
Remove the fuel rail assembly carefully to prevent damage to the injector electrical connector terminals and spray tips. Support the fuel rail after it is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system to prevent debris from entering open ports.


CAUTION
Fuel injection systems often remain pressurized, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the upper intake manifold with the lower intake manifold.
  6.  
  7. Remove the fuel pipe retaining clip.
  8.  
  9. Disconnect the fuel feed pipe from the fuel injector rail.
  10.  
  11. Use compressed air in order to remove debris from the area where the fuel injectors enter the intake manifold.
  12.  
  13. Remove the fuel rail bolts.
  14.  
  15. Remove the fuel rail with the fuel injectors.

    Click image to see an enlarged view

    Fig. Fuel rail removal 2.8L & 3.6L engines

  16.  
  17. Disengage the fuel injector electrical connector lock.
  18.  
  19. Disconnect the fuel injector electrical connector.
  20.  
  21. Remove the fuel injector retainer clip.
  22.  
  23. Remove the fuel injector.

    Click image to see an enlarged view

    Fig. Fuel injector removal 2.8L & 3.6L engines

  24.  

To install:

  1. Install the fuel injector.
  2.  
  3. Install the fuel injector retainer clip.

    Click image to see an enlarged view

    Fig. Fuel injector retainer clip installed 2.8L & 3.6L engines

  4.  
  5. Install the fuel injector electrical connector.
  6.  
  7. Engage the fuel injector electrical connector lock.
  8.  
  9. Install the fuel rail with the fuel injectors.
  10.  
  11. Install the fuel rail bolts and tighten to 89 inch. lbs. (10 Nm).
  12.  
  13. Connect the fuel feed pipe to the fuel rail.
  14.  
  15. Install the fuel pipe retaining clip.
  16.  
  17. Install the upper intake manifold.
  18.  

4.6L Engine

CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.


WARNING
Remove the fuel rail assembly carefully to prevent damage to the injector electrical connector terminals and spray tips. Support the fuel rail after it is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system to prevent debris from entering open ports.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
  6.  
  7. Disconnect the fuel feed pipe quick connect fitting from the fuel rail.
  8.  
  9. Disconnect the Positive Crankcase Ventilation (PCV) air tube quick connect fitting from the camshaft cover.
  10.  
  11. Reposition the surge tank inlet pipe hose clamp at the surge tank.
  12.  
  13. Remove the surge tank inlet pipe hose from the surge tank.
  14.  
  15. Reposition the surge tank inlet pipe hose clamp at the engine fitting.
  16.  
  17. Remove the surge tank inlet pipe hose from the engine fitting.
  18.  
  19. Remove the surge tank inlet pipe nuts.
  20.  
  21. Remove the surge tank inlet pipe from the fuel rail studs.
  22.  
  23. Disconnect the engine harness electrical connector from the starter solenoid cable electrical connector.
  24.  
  25. Disconnect the engine harness electrical connectors from the front fuel injectors.
  26.  
  27. Disconnect the engine harness electrical connectors (1) from the rear fuel injectors.
  28.  
  29. Remove the engine harness clip from the fuel rail stud.
  30.  
  31. Lay the harness aside.
  32.  
  33. Remove the fuel rail bracket retainer nut.
  34.  
  35. Remove the fuel rail studs.
  36.  
  37. Remove the fuel rail.

    Click image to see an enlarged view

    Fig. Fuel rail removal shown

  38.  
  39. Remove and discard the O-ring seals from the spray tip end of each fuel injector.
  40.  
  41. If replacing the fuel rail, remove the fuel injectors.
  42.  

To install:

  1. If the fuel rail was replaced, install the fuel injectors.
  2.  
  3. Install new O-ring seals to the spray tip end of each fuel injector.
  4.  
  5. Lubricate the new lower injector O-ring seals with clean engine oil.
  6.  
  7. Install the fuel rail.
  8.  
  9. Install the fuel rail studs and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Install the fuel rail bracket retainer nut and tighten to 89 inch lbs. (10 Nm).
  12.  
  13. Position the harness over the engine.
  14.  
  15. Install the engine harness clip to the fuel rail stud.
  16.  
  17. Connect the engine harness electrical connectors to the rear fuel injectors.
  18.  
  19. Connect the engine harness electrical connectors to the front fuel injectors.
  20.  
  21. Connect the engine harness electrical connector to the starter solenoid cable electrical connector.
  22.  
  23. Install the surge tank inlet pipe to the fuel rail studs.
  24.  
  25. Install the surge tank inlet pipe nuts.
  26.  
  27. Install the surge tank inlet pipe hose to the engine fitting.
  28.  
  29. Position the surge tank inlet pipe hose clamp at the engine fitting.
  30.  
  31. Install the surge tank inlet pipe hose to the surge tank.
  32.  
  33. Position the surge tank inlet pipe hose clamp at the surge tank.
  34.  
  35. Connect the PCV air tube quick connect fitting to the camshaft cover.
  36.  
  37. Connect the fuel feed pipe quick connect fitting to the fuel rail.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. Perform the following procedure in order to 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.
     

  42.  
  43. Install the fuel injector sight shield.
  44.  

5.7L & 6.0L Engines

WARNING
Remove the fuel rail assembly carefully to prevent damage to the injector electrical connector terminals and spray tips. Support the fuel rail after it is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system to prevent debris from entering open ports.


CAUTION
Fuel injection systems often remain pressurized, even after the engine has been turned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine sight shield.
  6.  
  7. Relieve fuel system pressure.
  8.  
  9. Clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rail in liquid cleaning solvent.
  10.  
  11. Remove the engine compartment fuel line.
  12.  
  13. Disconnect the engine compartment Evaporative Emission (EVAP) line from the chassis EVAP line.
  14.  
  15. Disconnect the fuel injector electrical connectors. Identify the connectors to their corresponding injectors in order to ensure the correct sequential injector firing order after reassembly.
  16.  
  17. Remove the fuel injector wiring harness retainers from the fuel rail.
  18.  
  19. Note the location of the fuel rail ground strap (1) on the intake manifold. The fuel rail ground strap must be installed during assembly.

    Click image to see an enlarged view

    Fig. Fuel rail ground strap 5.7L-6.0L engine

  20.  
  21. Remove the fuel rail attaching bolts.
  22.  
  23. Remove the fuel rail assembly.

    Click image to see an enlarged view

    Fig. Fuel rail assembly 5.7L-6.0L engine

  24.  
  25. Remove the injector lower O-ring seal from the spray tip end of each injector.
  26.  
  27. Discard the lower O-ring seals.
  28.  
  29. Remove the fuel injectors, if necessary.
  30.  
  31. Release the injector retainer clip.
  32.  
  33. Remove the infector from the fuel rail.
  34.  
  35. Remove the upper O-ring seal.
  36.  

To install:

  1. Install the fuel injectors, if previously removed.
  2.  
  3. Lubricate the upper O-ring seal with clean engine oil.
  4.  
  5. Install the fuel injector to the fuel rail with the electrical connector facing outward.
  6.  
  7. Secure the injector retainer clip.
  8.  
  9. Lubricate the new lower injector O-ring seals with clean engine oil.
  10.  
  11. Install the new O-ring seals on the spray tip end of each injector.
    CAUTION
    The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns.

  12.  
  13. Install the fuel rail assembly to the intake manifold.

    Click image to see an enlarged view

    Fig. Fuel rail assembly installation 5.7L-6.0L engine

  14.  
  15. Install the fuel rail attaching bolts and tighten to 89 inch lbs. (10 Nm).
  16.  
  17. Install the fuel injector wire harness retainers to the fuel rail.
  18.  
  19. Connect the fuel injector electrical connectors.
    NOTE
    Install each connector on the proper injector in order to ensure the correct sequential injector firing order. Rotate the injectors as required in order to avoid stretching the injector wiring harness.

  20.  
  21. Connect the engine compartment EVAP line to the chassis EVAP line.
  22.  
  23. Install the engine compartment fuel line.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Perform the following procedure in order to 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.
     

  28.  
  29. Install the fuel injector sight shield.
  30.  

 
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