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Fuel Rail & Injectors: Installation

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the NEW injector "O" ring seals, with clean engine oil. Install the new injector "O" ring seals onto the fuel injector. Install a new retainer clip onto the fuel injector.
  2. Push the fuel injector into the fuel rail injector socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail injector socket. Install the fuel rail.
  3. Apply a 0.2" (5 mm) band of GM threadlock US (12345382) or Canada (10953489), or equivalent to the threads of the fuel rail bolts. Install the fuel rail bolt and tighten to specification. See TORQUE SPECIFICATIONS .
  4. Install the fuel pressure regulator vacuum hose. Connect the fuel feed and return pipes to the fuel rail. See FUEL LINE DISCONNECT FITTINGS . Install the PCV hose.
  5. 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 on the connector in one click. Repeat the steps for each injector electrical connector.
  6. Position the engine wire harness. Connect the main coil and Fuel injector harness connectors to both sides of the engine. Install the harness clips to the fuel rail. Install the CPA retainers.
  7. Connect the Knock and MAP sensor harness connectors. Install the knock sensor harness connector to the intake manifold.
  8. Connect the EVAP purge solenoid electrical connector. Connect the generator electrical connector. Install the wire harness bracket nut and tighten to specification. See TORQUE SPECIFICATIONS .
  9. Tighten the fuel fill cap. Connect the negative battery cable.
  10. 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.
  11. Install engine sight shield. See ENGINE SIGHT SHIELD  under MISCELLANEOUS.


NOTE: When ordering new fuel injectors, you must order the correct injector for the application being serviced. The fuel injector is stamped with a identification part number. A four-digit build date code indicates the month, day, year, and shift that the injector was produced.
  1. Install NEW fuel injectors, if required. Lubricate the lower fuel injector "O" ring seals with clean engine oil. Install the fuel rail.
  2. Apply a 0.2" (5 mm) band of GM threadlock US (12345382) or Canada (10953489), or equivalent to the threads of the fuel rail bolts. Install the fuel rail bolt and tighten to specification. See TORQUE SPECIFICATIONS .
  3. Install the fuel pressure regulator vacuum hose. Connect the fuel feed and return pipes to the fuel rail. See FUEL LINE DISCONNECT FITTINGS . Install the PCV hose.
  4. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer on the connector in one click. Repeat the steps for each injector electrical connector.
  5. Position the engine wire harness. Connect the main coil and fuel injectors electrical connectors to both sides of the engine.
  6. Install the harness clips to the fuel rail. Install the CPA retainers. Connect the MAP sensor and Knock sensor electrical connectors. Install the knock sensor harness connector to the intake manifold.
  7. Connect the EVAP purge solenoid electrical connector. Connect the generator electrical connector. Install the wire harness bracket nut and tighten the nut to specification. Tighten the fuel fill cap. Connect the negative battery cable.
  8. 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.
  9. Install engine sight shield. See ENGINE SIGHT SHIELD  under MISCELLANEOUS.
Fig 1: Removing Fuel Rail (5.3L; Flex-Fuel)
G00232232Courtesy of GENERAL MOTORS CORP.


NOTE: When ordering new fuel injectors, you must order the correct injector for the application being serviced. The fuel injector is stamped with a identification part number. A four-digit build date code indicates the month, day, year, and shift that built the injector.
  1. Lubricate the new injector "O" ring seals with clean engine oil. Install the new injector "O" ring seals onto the injector. Install a new retaining clip on the injector.
  2. Push the fuel injector into the fuel rail with the electrical connector facing outwards. The retaining clip locks onto a flange on the fuel rail injector socket.
  3. Install fuel rail. Tighten studs to specification. See TORQUE SPECIFICATIONS . Install the fuel pressure regulator vacuum line.
  4. Connect the fuel feed and return pipes to the fuel rail. See FUEL LINE DISCONNECT FITTINGS .
  5. Install each fuel injector electrical connector onto the proper injector in order to ensure correct sequential injector firing order. Rotate the injectors as required in order to avoid stretching the wire harness.
  6. Reposition the engine harness. Install the engine harness bolt and studs and Tighten to specification. Connect the ETC electrical connector. Connect the EVAP canister purge valve electrical connector. Connect the generator electrical connector.
  7. Install the engine sight shield. See ENGINE SIGHT SHIELD  under MISCELLANEOUS. Install the fuel fill cap. Connect the negative battery cable. Tighten battery cable bolt to specification.
  8. Use the following procedure 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.
  9. Install engine sight shield. See ENGINE SIGHT SHIELD  under MISCELLANEOUS.
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