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Removal (4.8L, 5.3L & 6.0L)

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 injector harness connectors, do not use pliers or other hand tools, as connector ends may become damaged.
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. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .
  2. Remove the wire harness bracket nut. Disconnect the Evaporative (EVAP) emission purge solenoid harness connector. Disconnect the generator electrical connector.
  3. Disconnect harness connectors from the knock sensor and Manifold Absolute Pressure (MAP) sensor. See Figure. Remove the knock sensor harness connector from the intake manifold.
  4. Label injector harness connectors for installation reference. Pull Connector Position Assurance (CPA) on injector harness connector upward 1 click. See Fig 2. Push the tab on the connector in. Disconnect the fuel injector electrical connector. Disconnect remaining injector harness connectors in same manner.
  5. Remove the Positive Crankcase Ventilation (PCV) hose. See Figure. Remove the fuel pressure regulator vacuum hose.
  6. Disconnect fuel feed and return lines at fuel rail. See FUEL LINE DISCONNECT FITTINGS . Loosen crossover pipe-to-right fuel rail retainer screw. See Figure.
  7. 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.
  8. Remove fuel rail retaining bolts. Remove fuel rail from intake manifold. Remove and discard the fuel injector retainer clip. Remove the fuel injector. Remove and discard the fuel injector retainer clip. Remove and discard the fuel injector "O" ring seals.
Fig 1: Exploded View Of Fuel Rail Components (8.1L)
G00156242Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing/Installing Fuel Injector Harness Connectors (4.8L, 5.3L & 6.0L)
G00156239Courtesy of GENERAL MOTORS CORP.
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