GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2009 🢒 Sportwagon 🢒 Engine 🢒 Engine Controls and Fuel - 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Before removal, clean the fuel rail assembly with a spray type engine cleaner, if necessary. Follow the package instructions. Do not soak fuel rails in liquid cleaning solvent.

    3. Notice: 

       • Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
       • Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.

  3. Disconnect the fuel feed hose from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .

    4. Object Number: 1950743 Size: SH

    Important: Identify the connectors to their corresponding injectors to make sure correct sequential injector firing order after reassembly.

  4. Disconnect the injector electrical connectors (2) to the injectors.

    5. Object Number: 1954074 Size: SH
  5. Disconnect the electrical harness from the fuel rail brackets.
  6. Remove the fuel rail ground strap to intake manifold retaining bolt (1).
  7. Remove the fuel rail to intake manifold retaining bolts (2).
  8. Lift evenly on both sides of the fuel rail , and remove the fuel rail assembly.

    9. Object Number: 1954075 Size: SH
  9. Remove the injector lower O-ring seal (2) from the spray tip end of each injector and discard.

    10. Discard the O-ring seals.

Installation Procedure

    Object Number: 1954075 Size: SH
  1. Lubricate the NEW lower injector O-ring seals (2) with clean engine oil.
  2. Install the new O-ring seals (2) on the spray tip end of each injector.

    3. Object Number: 1954074 Size: SH
  3. Install the fuel rail assembly to the intake manifold.
  4. Apply a 0.5 mm (0.020 in) band of approved threadlock to the threads of the fuel rail retaining bolts.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the fuel rail to intake manifold retaining bolts (2).

    6. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  6. Install the fuel rail ground strap to intake manifold retaining bolts (1).

    7. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1950743 Size: SH
  7. Connect the injector electrical connectors (1) to the injectors.
    8. • Install each connector on the proper injector in order to make sure correct sequential injector firing order.
    • Rotate the injectors as required in order to avoid stretching the wire harness.
  8. Connect the electrical harness to the fuel rail brackets.
  9. Connect the fuel feed hose to the fuel rail fuel pipe. Refer to Metal Collar Quick Connect Fitting Service .
  10. Connect the negative battery cable.
  11. Inspect for leaks.
    12. 11.1. Turn ON the ignition for 2 seconds.
    11.2. Turn OFF the ignition for 10 seconds.
    11.3. Turn ON the ignition.
    11.4. Inspect for fuel leaks.