Fuel Injection Fuel Rail Assembly Replacement

Courtesy of GENERAL MOTORS COMPANY

Callout	Component Name
WARNING: High Pressure Lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1600 Bar (23200 psi). Use extreme caution when inspecting for high pressure leaks. Fuel under this amount of pressure can penetrate skin causing personal injury, or death. Wear safety goggles and adequate clothing when servicing this fuel system. Preliminary Procedures Turn OFF the engine for 30 seconds before proceeding. This will ensure fuel pressure has purged from the fuel system. Remove and DISCARD the fuel feed pipe (fuel pump to fuel rail). Fuel Injection Fuel Feed Pipe Replacement (Fuel Pump to Fuel Rail) Remove and DISCARD the fuel injection fuel feed pipes (fuel injectors to fuel rail). Fuel Injection Fuel Feed Pipe Replacement (Fuel Injector to Fuel Rail) Disconnect the electrical connectors. NOTE: The fuel feed pipes are one time use ONLY. The fuel feed pipes MUST be replaced whenever they are loosened.
1	Diesel Fuel Separator Hose Clamp
2	Diesel Fuel Separator Hose Procedure Remove the diesel fuel separator hose from the fuel injection fuel rail.
3	Fuel Injection Fuel Rail Fastener [2x] CAUTION: Refer to Fastener Caution . Tighten 25 N.m (18 lb ft)
4	Fuel Injection Fuel Rail Procedure Prime the fuel system. Fuel System Priming With the engine running, check the fuel system for leaks. Replace the fuel filter. Fuel Filter Replacement If replacing, perform the fuel injection small quantity learn. Fuel Injection Small Quantity Learn If replacing, perform the high pressure fuel correction reset. High Pressure Fuel Correction Reset