LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2024 >> Traverse Z71 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 2.5L (LK0) - Repair Instructions >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

  1. GM5064715Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The fuel injector seal spacer is directional. If installed in the incorrect orientation, a fuel leak can result. When installed correctly, the fuel injector seal spacer will be flush with the injector.

    Fuel Injector Seal Spacer (1) - Install NEW [4x]

  2. Fuel Injection Fuel Rail Seal (2) - Install NEW [4x]
    3. NOTE:

    Arrows show proper orientation to install the bushing. Will fit flush against the injector.

  3. Fuel Injector Bushing (3) - Install NEW [4x]
  4. GM5064709Courtesy of GENERAL MOTORS COMPANY

    Holding the largest diameter / body (2) of the injector only, insert the injector assembly (2) into the fuel rail. Ensure correct orientation of the electrical connector.

  5. Fuel Injector Retainer (1) - Install NEW [4x]
  6. GM4840511Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    DO NOT use any type of lubricant when installing the NEW combustion seals on the fuel injector tip.

    Install EN-51955-1  Long Protector (1) onto the fuel injector tip, covering the first recessed area closest to the tip. Place a NEW fuel injector nozzle housing seal (2) on EN-51955-1  Long Protector (1).

  7. Using EN-51955-4  Pusher (3), install the fuel injector nozzle housing seal (2) into the recessed area (4) of the fuel injector, then remove the EN-51955-1  Long Protector.
  8. Compress the fuel injector nozzle housing seal (2) using EN-51955-3  Pre-Sizer (5).
  9. Using EN-51955-5  Sizer (6), resize the fuel injector nozzle housing seal.
  10. Install EN-51955-2  Short Protector (7) onto the fuel injector tip. Place a second NEW fuel injector nozzle housing seal (8) on EN-51105-2  Short Protector (7).
  11. Using EN-51955-4  Pusher (3), install the fuel injector nozzle housing seal (8) into the remaining recessed area (9) of the fuel injector, then remove EN-51105-2  Short Protector.
  12. Compress the fuel injector nozzle housing seal (8) using EN-51955-3  Pre-Sizer (5).
  13. Using EN-51955-5  Sizer (6), resize the fuel injector nozzle housing seal.
  14. GM2918356Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The fuel injector nozzle housing seals must fit properly in the relative groove. Overlapping of the fuel injector nozzle housing seals with the external surface of the injector must be avoided.

    Check both of the fuel injector nozzle housing seals on each fuel injector for correct seat:

    • The fuel injector nozzle housing seal must not be too large, buckled, or corrugated (1)
    • The fuel injector nozzle housing seal must be fixed tight and accurate (2)
  15. If the fuel injector nozzle housing seals are not installed correctly, remove the incorrect fuel injector nozzle housing seal and replace with a NEW fuel injector nozzle housing seal.
  16. GM6412143Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Start the direct fuel injection fuel rail bolts by hand then draw the direct fuel injection fuel down evenly prior to tightening.

    Install the direct fuel injection fuel rail (2) to the cylinder head.

    17. CAUTION:

    Refer to Fastener Caution .

  17. Fuel Injection Fuel Rail Bolt (1) @ Direct Fuel Injection Fuel Rail (2) - Install and tighten [4x] - Fastener Specifications
  18. GM6407852Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    To tighten or loosen the fuel injection fuel rail fuel pressure sensor, apply force ONLY to the attached hexagon. Applying force to the plastic housing of the sensor may damage the sensor.

    NOTE:

    Ensure the fuel rail threads are clean and free of any excess fuel, or the fuel rail pressure sensor will NOT seal properly.

    Lubricate the threads and sealing surface of the fuel rail pressure sensor (1) with one drop of clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

  19. Install the fuel rail pressure sensor (1) and hand tighten.
  20. Remove the fuel rail pressure sensor (1) from the fuel injection fuel rail and re-lubricate with one drop of clean engine oil. Adhesives, Fluids, Lubricants, and Sealers
    21. CAUTION:

    Refer to Component Fastener Tightening Caution .

  21. Fuel Rail Pressure Sensor (1) - Install and tighten - Fastener Specifications
  22. GM6552037Courtesy of GENERAL MOTORS COMPANY

    Install the fuel injector wiring harness (3).

  23. Connect the 8 fuel injector wiring harness connectors (2).
  24. Tie Strap (1) - Install NEW [4x]
  25. GM6411604Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Fuel Injection Fuel Rail Noise Shield (1) - Install

  26. GM6402123Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Gasket @ Intake Manifold (1) - Install NEW

  27. GM6401283Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold (2) - Install

  28. Intake Manifold Bolt (1) - Install and hand tighten [5x]
  29. Intake Manifold Bolt (1) - Tighten in sequence [5x] - Fastener Specifications
  30. GM6401282Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Cover (1) - Install

  31. Connect the electrical connectors and install the wiring harness retainers as necessary.
  32. Oil Level Indicator - Install
  33. GM6401280Courtesy of GENERAL MOTORS COMPANY

    Oil Level Indicator Tube Bracket Bolt (2) - Install and tighten - Fastener Specifications

  34. Intake Manifold Cover Bolt (1) - Install and tighten [3x] - Fastener Specifications
  35. GM6382791Courtesy of GENERAL MOTORS COMPANY

    Install the hose retainers as necessary.

  36. GM6382749Courtesy of GENERAL MOTORS COMPANY

    Install the hose retainers as necessary.

  37. GM6401278Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Coolant Hose (2) - Install

  38. Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Install and tighten - Fastener Specifications
  39. GM6396386Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bracket (1) - Install

  40. GM6396387Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bracket Bolt (1) - Install and tighten [4x] - Fastener Specifications

  41. GM6396382Courtesy of GENERAL MOTORS COMPANY

    Fuel Feed Intermediate Pipe (2) - Install NEW

  42. Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe - Tighten [2x] - Fastener Specifications
  43. Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Install and tighten - Fastener Specifications
  44. Retainer (3) - Engage
  45. GM6382618Courtesy of GENERAL MOTORS COMPANY

    Radiator Surge Tank Outlet Pipe (2) - Install

  46. Radiator Surge Tank Outlet Pipe Nut (1) - Install and tighten - Fastener Specifications
  47. GM6396384Courtesy of GENERAL MOTORS COMPANY
    WARNING:

    The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

    Fuel Pump Insulator (1) - Install

  48. GM6396378Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler (1) - Install

  49. GM6396375Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Coolant Hose Clamp (4) - Tighten - Fastener Specifications

  50. Charge Air Cooler Coolant Hose (3) - Install [2x]
  51. Charge Air Cooler Coolant Hose Retainer (2) - Engage [2x]
  52. Charge Air Cooler Outlet Air Hose Clamp (1) - Tighten - Fastener Specifications
  53. Connect the electrical connector. (5)
  54. GM6396374Courtesy of GENERAL MOTORS COMPANY

    Charge Air Cooler Bolt (1) - Install and tighten [4x] - Fastener Specifications

  55. GM6405033Courtesy of GENERAL MOTORS COMPANY

    Air Cleaner Outlet Duct (4) - Install

  56. Air Cleaner Outlet Duct Nut (3) - Install and tighten - Fastener Specifications
  57. Air Cleaner Outlet Duct Bolt (2) - Install and tighten [2x] - Fastener Specifications
  58. Air Cleaner Outlet Duct Clamp (5) - Tighten - Fastener Specifications
  59. Turbocharger Outlet Duct Front Clamp (1) - Tighten - Fastener Specifications
  60. GM6396380Courtesy of GENERAL MOTORS COMPANY

    Positive Crankcase Ventilation Fresh Air Tube (1) @ Air Cleaner Outlet Duct - Connect - Plastic Collar Quick Connect Fitting Service 

  61. GM6382159Courtesy of GENERAL MOTORS COMPANY

    Oil Filler Cap (1) - Remove

  62. GM6382158Courtesy of GENERAL MOTORS COMPANY

    Intake Manifold Cover (1) - Install

  63. GM6382159Courtesy of GENERAL MOTORS COMPANY

    Oil Filler Cap - Install

  64. Fill the cooling system to the proper level. Cooling System Draining and Filling (GE 47716)
  65. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
  66. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition with the engine OFF.
    4. Inspect for fuel leaks.
scientia non olet · About LEMON Manuals