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Removal & Installation (4.8L, 5.3L & 6.0L)

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CAUTION: An eight-digit identification number (1) is located on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required. See Fig 1.
CAUTION: The Denso fuel injectors that are installed in the 5.3L (L59) E85 application will not have "O" rings and retaining clips serviced separately. The fuel injectors will be replaced whenever an "O" ring or clips needs to be replaced.
CAUTION: The engine oil may be contaminated with fuel if the fuel injectors are leaking.
NOTE: Before removal, if necessary, clean the fuel rail assembly with a spray type engine cleaner, use GM X-30A or equivalent. Follow the package instructions. DO NOT soak fuel rail assembly in any liquid cleaning solvent.
NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. DO NOT immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
  1. Remove the engine cover. Remove the air cleaner resonator outlet duct.
  2. Disconnect the accelerator control cable and the cruise control cable from the cable bracket, if equipped. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever, if equipped. See Fig 2.
  3. Disconnect the accelerator control cable and the cruise control cable from the throttle body, if equipped. Remove the upper engine wire harness retainer nut. See Fig 3.
  4. Disconnect the Evaporative (EVAP) Emission purge valve harness connector. Reposition the upper engine wire harness aside. Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE .
  5. Mark the electrical connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
    6. 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.
  6. Pull the Connector Position Assurance (CPA) (2) on the injector connector up. Push the tab (1) on the injector connector in. While pushing the tab (1) on the injector connector in, release the CPA (2). See Fig 4.
  7. Repeat step  6 for the remaining fuel injector connector electrical connectors. See Fig 5.
    8. 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.
  8. Disconnect the fuel feed and return pipes from the fuel rail. Disconnect the fuel pressure regulator vacuum line. Loosen the crossover tube to right fuel rail retainer screw. See Fig 6. Remove the fuel rail bolts. Remove the fuel rail. Remove and discard the fuel injector lower "O" ring seals from the injectors. See Fig 7.
Fig 1: Locating Fuel Rail Identification Number (4.8L, 5.3L & 6.0L)
G00252117Courtesy of GENERAL MOTORS CORP.
Fig 2: Disconnecting Cruise Control Cable Engine-End Fitting (4.8L, 5.3L & 6.0L)
G00252118Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing Upper Engine Wire Harness Retaining Nut (4.8L, 5.3L & 6.0L)
G00255718Courtesy of GENERAL MOTORS CORP.
Fig 4: Disconnecting Fuel Injector Connectors (4.8L, 5.3L & 6.0L - 1 Of 2)
G00255719Courtesy of GENERAL MOTORS CORP.
Fig 5: Disconnecting Fuel Injector Connectors (4.8L, 5.3L & 6.0L - 2 Of 2)
G00255720Courtesy of GENERAL MOTORS CORP.
Fig 6: Removing/Installing Fuel Rail Retaining Screw (4.8L, 5.3L & 6.0L)
G00255721Courtesy of GENERAL MOTORS CORP.
Fig 7: Exploded View Of Fuel Injector Components (4.8L, 5.3L & 6.0L)
G00255722Courtesy of GENERAL MOTORS CORP.
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