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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1168 (Engine Controls - 6.0L - Alternative Fuels (Introduction)) >> Repair Instructions >> Fuel Rail Assembly Replacement (KL6) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Refer to Compressed Natural Gas (CNG) Flammability Caution in Cautions and Notices.
    CAUTION: Refer to Compressed Natural Gas (CNG) Fuel Pressure Relief Caution in Cautions and Notices.
  1. Relieve the CNG fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Relieve the gasoline fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls in the C/K Pickup service manual.
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical in the C/K Pickup service manual.
  4. Before removal, clean the fuel rail assemblies with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak fuel rails in liquid cleaning solvent.
    5. Fig 1: View Of Top Engine Cover
    GM665886Courtesy of GENERAL MOTORS CORP.
  5. Remove the engine sight shield. Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines) Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88) in Engine Mechanical in the C/K Pickup service manual.
    6. Fig 2: Identifying IPR Fuel Outlet Lines Components
    GM757010Courtesy of GENERAL MOTORS CORP.
  6. Loosen and remove the fuel line to rail clamps (9).
  7. Remove the fuel line retainers (7).
  8. Disconnect the fuel lines (5, 8) from the fuel rails (1, 10).
    9. Fig 3: Identifying Fuel Injector Connectors
    GM757006Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel rail temperature and pressure sensor electrical connectors (7, 2).
    10. IMPORTANT: Identify the injector connectors to their corresponding engine cylinder to ensure correct sequential injector firing order after reassembly.
  10. Disconnect the 8 CNG fuel injector electrical connectors (6).
    11. Fig 4: Locating Accelerator Control Cable and Cruise Control Cable
    GM389853Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the accelerator control cable and the cruise control cable from the cable bracket (if equipped).
    12. Fig 5: View Of Accelerator/Throttle Cable
    GM389031Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the accelerator control cable and the cruise control cable from the throttle body (if equipped).
    13. Fig 6: Identifying Upper Engine Wire Harness Retainer
    GM310125Courtesy of GENERAL MOTORS CORP.
  13. Remove the upper engine wire harness retainer nut.
  14. Disconnect the evaporative emission (EVAP) purge valve harness connector.
  15. Reposition the upper engine wire harness aside.
    16. Fig 7: Identifying Lock Release
    GM372749Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Identify the connectors to their corresponding gasoline injectors to ensure correct sequential injector firing order after reassembly.
  16. Pull the top portion (2) of the injector connector up. Do not pull the top portion of the connector past the top of the white portion (1).
    17. Fig 8: Disconnecting Fuel Injector Electrical Connectors
    GM372753Courtesy of GENERAL MOTORS CORP.
  17. Push the tab (1) on the lower side of the injector connector in order to release the connector from the injector.
  18. Repeat Step 16 and Step 17 for each gasoline injector connector.
    19. Fig 9: 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.
  19. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
  20. Disconnect the fuel pressure regulator vacuum line.
    21. Fig 10: Identifying Fuel Rail Assembly Components
    GM798436Courtesy of GENERAL MOTORS CORP.
  21. Loosen the crossover tube (3) to right fuel rail retainer screw.
    22. Fig 11: Locating Left Fuel Rail Attaching Bolts
    GM798435Courtesy of GENERAL MOTORS CORP.
  22. Remove the left fuel rail attaching bolts (3, 4).
    23. Fig 12: Locating Right Fuel Rail Attaching Bolts
    GM798434Courtesy of GENERAL MOTORS CORP.
  23. Remove the right fuel rail attaching bolts (3).
    24. Fig 13: Identifying Fuel Rail Assembly Components
    GM798436Courtesy of GENERAL MOTORS CORP.
  24. Remove the gasoline and CNG fuel rails (1, 8, 4, 5) as an assembly.
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