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Home >> Chevrolet >> 2005 >> Chevy Express G3500, Van Passenger Extended >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 4.8L, 5.3L, And 6.0L - Introduction >> Repair Instructions >> Fuel Rail Assembly Replacement >> Removal Procedure

Removal Procedure

  1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  2. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
    3. IMPORTANT: An eight-digit identification number (1) is located on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required.
    Fig 1: Fuel Rail Identification Number Location
    GM380659Courtesy of GENERAL MOTORS CORP.
  3. Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. Do not soak fuel rail assembly in any liquid cleaning solvent.
    4. Fig 2: Locating Accelerator Control Cable and Cruise Control Cable
    GM389853Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the accelerator control cable and the cruise control cable from the cable bracket, if equipped.
    5. Fig 3: Cruise Control Cable End & Throttle Linkage
    GM1199275Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever, if equipped.
    6. Fig 4: View Of Accelerator/Throttle Cable
    GM389031Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the accelerator control cable and the cruise control cable from the throttle body, if equipped.
    7. Fig 5: Identifying Upper Engine Wire Harness Retainer
    GM310125Courtesy of GENERAL MOTORS CORP.
  7. Remove the upper engine wire harness retainer nut.
  8. Disconnect the evaporative emission (EVAP) purge valve harness connector.
  9. Reposition the upper engine wire harness aside.
  10. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
    11. Fig 6: Pulling CPA Of Injector Connector Up
    GM820976Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When disconnecting the Multec 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable.
  11. Mark the electrical connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
  12. Pull the connector position assurance (CPA) (2) on the injector connector up.
  13. Push the tab (1) on the injector connector in.
    14. Fig 7: CPA Retainer & Tab
    GM820977Courtesy of GENERAL MOTORS CORP.
  14. While pushing the tab (1) on the injector connector in, release the CPA (2).
  15. Disconnect the fuel injector connector electrical connector.
  16. Repeat steps for each injector connector.
    17. Fig 8: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • 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.
  17. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
  18. Disconnect the fuel pressure regulator vacuum line.
    19. Fig 9: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
  19. Loosen the crossover tube to right fuel rail retainer screw (22).
    20. Fig 10: View Of Fuel Rail
    GM376389Courtesy of GENERAL MOTORS CORP.
  20. Remove the fuel rail bolts.
  21. Remove the fuel rail.
    22. Fig 11: View Of Fuel Injector, Clip & O-Rings
    GM351185Courtesy of GENERAL MOTORS CORP.
  22. Remove and discard the fuel injector lower O-ring seals (4) from the injectors (3).
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