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Removal (8.1L)

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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. Remove intake manifold sight shield from top of engine. Remove intake manifold sight shield bracket nuts and bracket.
  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 harness connectors from EVAP purge solenoid, generator, Throttle Position (TP) sensor and Electronic Throttle Control (ETC). Remove upper engine wiring harness bracket studs. Position upper engine wiring harness aside.
    4. CAUTION: When disconnecting injector harness connectors, DO NOT use pliers or other hand tools, as connector ends may become damaged.
  4. Label injector harness connectors for installation reference. Pull fuel injector harness connector top upward, but not past the White portion of the connector. See Fig 1. Push fuel injector harness connector release tab inward, to release connector from fuel injector. Disconnect remaining injector harness connectors in same manner.
  5. Remove the fuel rail assembly carefully in order to prevent damage to the fuel injector harness connector terminals and the fuel 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.
  6. Disconnect the fuel feed and return lines from the fuel rail. Disconnect fuel pressure regulator vacuum line. Remove the fuel rail attaching bolts and remove the fuel rail. Remove fuel injector retainer(s) and remove fuel injector(s) from fuel rail. See Fig 2. Remove and discard fuel injector "O" rings.
Fig 1: Removing Fuel Injector Harness Connectors (8.1L)
G00156241Courtesy of GENERAL MOTORS CORP.
Fig 2: Exploded View Of Fuel Rail Components (8.1L)
G00156242Courtesy of GENERAL MOTORS CORP.
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