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Home >> Pontiac >> 2004 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 120 (Engine Control System - 4.8L, 5.3L, & 6.0L - Introduction) >> Repair Instructions >> Fuel Rail Assembly Replacement >> Installation Procedure
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Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 Chevrolet TrailBlazer, and 2004 Buick Rainier. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Injector, Clip & O-Rings
    GM351185Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the NEW lower injector O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto each injector, if necessary.
    3. Fig 2: Removing/Installing Fuel Rail Bolts
    GM376389Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel rail.
  4. Apply a 5 mm (0.020 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel rail bolts.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the fuel rail bolts.

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

    6. Fig 3: View Of EVAP/Fuel Hose/Pipes
    GM856643Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel pressure regulator vacuum line.
  7. Connect the fuel feed and return pipes (1) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    8. Fig 4: Removing/Installing Upper Engine Wire Harness Retainer Nut
    GM899740Courtesy of GENERAL MOTORS CORP.
  8. Position the upper engine wire harness over the engine.
  9. Install the upper engine wire harness retainer nut (1).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

    10. Fig 5: Breather Crossover Tube View
    GM647793Courtesy of GENERAL MOTORS CORP.
  10. Install the PCV hose (with valve).
    11. Fig 6: Top Of Engine Wiring Harness View
    GM898326Courtesy of GENERAL MOTORS CORP.
  11. Connect the following electrical connectors on the left hand side of the engine:
    • EVAP purge solenoid (1)
    • Knock sensor (2)
    • MAP sensor (3)
    • Main coil (5)
    • Fuel injectors (4)
    12. Fig 7: Disconnecting/Connecting Fuel Injector Electrical Connectors
    GM1209783Courtesy of GENERAL MOTORS CORP.
  12. Perform the following steps in order to Connect the fuel injector electrical connectors.
    1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    2. Connect the fuel injector electrical connector.
    3. Push the CPA retainer (2) on the connector in 1 click.
    4. Repeat the steps for each injector electrical connector.
  13. Install the electrical harness to the clips on ignition coil bracket.
    14. Fig 8: Locating Electrical Components At Top Of Engine
    GM898331Courtesy of GENERAL MOTORS CORP.
  14. Connect the following electrical connectors on the right hand side of the engine:
    • Coil main electrical harness (1)
    • ETC (2)
    • Fuel injectors (3)
  15. Install the electrical harness to the clips on ignition coil bracket.
    16. Fig 9: Disconnecting/Connecting Generator Electrical Connector
    GM898329Courtesy of GENERAL MOTORS CORP.
  16. Connect the generator electrical connector.
    17. Fig 10: View Of MAF/IAT Sensor Electrical Connector
    GM1204792Courtesy of GENERAL MOTORS CORP.
  17. Connect the MAF/IAT sensor electrical connector (1).
    18. Fig 11: View Of A/C Compressor Pressure Switch Electrical Connector & Retaining Clip
    GM898468Courtesy of GENERAL MOTORS CORP.
  18. Install the wire harness to the clip (1) on the cylinder head.
  19. Connect the A/C compressor pressure switch electrical connector (2).
  20. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement 
  21. Install the fuel fill cap.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  23. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
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