GM 12596245 Rail Assembly, Multiport Fuel Injection Fuel

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To remove the fuel injectors, start by relieving the fuel system pressure and disconnecting the negative battery terminal. Then, remove the air intake duct and coolant overflow pipe if necessary. Release the quick-connect line fitting at the fuel rail and disconnect the electrical connectors from the fuel injectors. Remove the fuel rail mounting bolts and remove the fuel rail and injectors as a single assembly. Remove the retainer securing each fuel injector to the fuel rail and pull out the injector. Remove the old O-rings from each injector and discard them. For installation, lubricate the new injector O-rings with clean engine oil and tighten the fuel rail mounting bolts to the proper torque specifications. Reconnect the battery and start the engine to check for fuel leaks. On turbocharged engines, additional steps include removing the fuel rail high-pressure feed pipe and intake manifold. Carefully remove the foam fuel injector insulator, electrical connectors, and any remaining connections. Remove the fuel rail, using a special injector removal tool if necessary. Remove the old Teflon sealing ring and upper O-ring from each injector. To install the new Teflon seal, use the special tools included in the injector tool set or a socket of similar diameter. Install the support ring, upper O-ring, and Teflon seal on each injector. Clean the injector bores and install the spring steel retainer on each injector. Install the fuel rail and injectors, tightening the mounting bolts and high-pressure fuel line fittings to the correct torque specifications. Reconnect the battery and start the engine to check for fuel leaks.

To remove the fuel system, start by relieving the fuel system pressure and equalizing the tank pressure by removing the fuel filler cap. Disconnect the cable from the negative battery terminal and remove the air intake duct on four-cylinder models or the upper intake manifold on V6 models. Disconnect all interfering wiring, including the connectors at each fuel injector, and move the harnesses out of the way. Remove the fuel supply line from the fuel rail and remove the old o-rings, as well as the fuel rail mounting bolts. Remove the fuel rail and injectors as a single assembly, ensuring no o-rings remain in the injector holes. Remove the retainer securing each fuel injector to the fuel rail and pull out the injector, and install new o-rings to the injector.

After removing the fuel injectors, the old O-rings from each injector should be removed and discarded. For installation, lubricate the new injector O-rings with clean engine oil and tighten the fuel rail mounting bolts to the proper torque specifications.

After installing the fuel rail and injectors, tighten the mounting bolts and high-pressure fuel line fittings to the correct torque specifications. Reconnect the battery and start the engine to check for fuel leaks.

To remove fuel injectors in four-cylinder models, follow these steps:Clean the fuel injector areas with compressed air.Unbolt the fuel line support bracket.Disconnect the fuel line from the rail and the quick-connect fitting.Disconnect the wiring from the fuel injectors.Remove the fuel rail mounting bolts.Extract the fuel rail along with its injectors.Release the fuel injector retaining clips and remove each injector, discarding the upper and lower O-rings.