2003 Chevrolet SSR BaseFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    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) on the spray tip end of each injector (3).
    3. Fig 2: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
  3. Remove the crossover tube to the right fuel rail retainer (21).
  4. Remove the crossover tube (25) from the right fuel rail (15).
  5. Remove the O-ring (20) from the crossover tube (25).
  6. Install a new O-ring on the crossover tube.
  7. Lubricate the new O-ring with clean engine oil.
  8. Install the crossover tube (25) into the right fuel rail (15).
  9. Loosely install the crossover tube to the right fuel rail retainer (21).
    10. Fig 3: Removing/Installing Fuel Rail Bolts
    GM376389Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel rail assembly to the intake manifold.
  11. Apply a 5 mm (0.020 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock, or equivalent, to the threads of the fuel rail bolts.
  12. Install the fuel rail attaching bolts.

    Tighten: 

    1. Tighten the bolts to 10 N.m (89 lb in).
    2. Tighten the right crossover pipe retainer screw to 3.8 N.m (34 lb in).

    13. Fig 4: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel pressure regulator vacuum line.
  14. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
  15. Connect the injector electrical connectors.
    • Install each connector on 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.
    16. Fig 5: View Of Upper Engine Wire Harness
    GM310125Courtesy of GENERAL MOTORS CORP.
  16. Position the upper engine wire harness in place.
  17. Connect the EVAP purge solenoid connector.
  18. Install the retainer nut to the upper engine wire harness.

    Tighten:  Tighten the nut to 5.5 N.m (49 lb in).

    19. Fig 6: Locating Accelerator Control Cable and Cruise Control Cable
    GM389853Courtesy of GENERAL MOTORS CORP.
  19. Connect the accelerator control cable and the cruise control cable to the cable bracket.
    20. Fig 7: View Of Accelerator/Throttle Cable
    GM389031Courtesy of GENERAL MOTORS CORP.
  20. Connect the accelerator control cable and the cruise control cable to the throttle body.
  21. Install the engine sight shield mounting bracket and the bolts. Refer to Engine Sight Shield Replacement in Engine Mechanical.
  22. Tighten the fuel filler cap.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  24. Use the following procedure in order to inspect for leaks:
    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.
  25. Install the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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