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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 387 (Engine Controls - Removal & Installation - Flex Fuel & Gasoline) >> Fuel Systems >> Fuel Rail & Injectors >> Removal (5.3L Flex-Fuel)

Removal (5.3L Flex-Fuel)

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: 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.
NOTE: The flex-fuel rail is comprised of a material that is compatible with fuel that has a concentration of up to 85 percent ethanol. The flex-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. An 8-digit identification number is located on the fuel rail. Refer to this model identification number if service or part replacement is required.
NOTE: The Denso fuel injectors installed on the E85 application will NOT have "O" rings and retaining clips serviced separately. Therefore the fuel injectors will be replaced whenever an "O" ring or clip needs to be replaced.
  1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .
  2. 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. Remove upper engine wiring harness retainer nut.
  3. Remove the wire harness bracket nut. Disconnect the Evaporative (EVAP) emission purge solenoid harness connector. Disconnect the generator electrical connector.
  4. Disconnect harness connectors from the Knock sensor and Manifold Absolute Pressure (MAP) sensor. Reposition upper engine wiring harness aside.
  5. Remove PCV hose. Remove fuel pressure regulator vacuum line. Label injector harness connectors for installation reference.
  6. Pull Connector Position Assurance (CPA) on injector harness connector upward one click. See Figure. Push the tab on the connector in. Disconnect the fuel injector electrical connector. Disconnect remaining injector harness connectors in same manner.
  7. Disconnect fuel feed and return lines at fuel rail. See FUEL LINE DISCONNECT FITTINGS .
  8. Remove fuel rail retaining bolts. See Figure. Remove fuel rail from intake manifold. Inspect the fuel injector lower "O" ring seals of each fuel injector for damage. Replace the fuel injectors as needed.
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