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Removal (4.8L, 5.3L & 6.0L)

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CAUTION: Two different fuel rails exist for 5.3L. The standard 5.3L (RPO code LM7) uses a gasoline-only fuel rail. The optional 5.3L (RPO code L59) uses a flex-fuel E85 fuel rail. The E85 fuel rail is comprised of a material that is compatible with fuel that has a concentration of up to 85 percent ethanol. The E85 fuel rail also uses E85 denso fuel injectors. Because of this, special procedures will be used in servicing the fuel rail and associated components. The screws that fasten the retaining clips for the crossover pipe to the fuel rails are thread cutting and therefore should NOT be removed from the fuel rail. The fuel rail will be serviced as an entire component.
NOTE: An 8-digit part identification number can be found on the fuel rail assembly. Refer to this number if service or part replacement is necessary.
  1. Disconnect negative battery cable. Loosen retaining bolt on intake manifold sight shield at top of engine. See Figure. Remove intake manifold sight shield from top of engine. Remove intake manifold sight shield retainer bolts. Unclip accelerator cable from intake manifold sight shield retainer. Remove intake manifold sight shield retainer.
  2. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Before removal, clean fuel rail assembly with a spray type engine cleaner, such as GM X-30A. DO NOT use any solvent that contains Methyl Ethyl Ketone (MEK). Solvents containing MEK may damage fuel system components.
  3. Disconnect accelerator and cruise control cables from cable bracket. Disconnect accelerator and cruise control cables from throttle body.
  4. Remove upper engine wiring harness retainer nut. Disconnect EVAP purge solenoid harness connector. Disconnect harness connectors from Throttle Position (TP) sensor, knock sensor and Manifold Absolute Pressure (MAP) sensor. Reposition upper engine wiring harness aside.
    5. CAUTION: When disconnecting injector harness connectors, DO NOT use pliers or other hand tools, as connector ends may become damaged.
  5. Label injector harness connectors for installation reference. Pull Connector Position Assurance (CPA) on injector harness connector upward. See Fig 1. While pushing injector harness connector tab inward, release CPA. Disconnect injector harness connector. Disconnect remaining injector harness connectors in same manner.
  6. Disconnect fuel feed and return lines at fuel rail. See FUEL LINE DISCONNECT FITTINGS . Disconnect fuel pressure regulator vacuum line. On models equipped with gasoline-only 5.3L (RPO code LM7), loosen crossover pipe-to-right fuel rail retainer screw. See Fig 2.
  7. On all models, remove fuel rail retaining bolts. Remove fuel rail from intake manifold. Remove fuel injector retainer(s) and remove fuel injector(s) from fuel rail. Remove injector "O" rings and discard.
Fig 1: Removing/Installing Fuel Injector Harness Connectors (4.8L, 5.3L & 6.0L)
G00156239Courtesy of GENERAL MOTORS CORP.
Fig 2: Exploded View Of Fuel Rail (4.8L, 5.3L & 6.0L)
G00156240Courtesy of GENERAL MOTORS CORP.
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