Removal (Bi-Fuel)
WARNING: This page is about a different car, the 2003 GMC Savana and 2003 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
- Relieve the CNG fuel system pressure before servicing. See FUEL SYSTEM PRESSURE RELEASE . Relieve gasoline fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in CHEVY EXPRESS & SAVANA - GASOLINE article.
- Disconnect the negative battery cable. Remove the engine cover. See ENGINE COVER under MISCELLANEOUS.
- Disconnect the CNG fuel lines (7, 8 and 10) from the fuel rails. See Figure. Disconnect the fuel rail temperature and pressure sensor electrical connectors (3 and 4). Disconnect the low pressure lock-off solenoid connector. Disconnect the eight CNG fuel injector electrical connectors (2 and 12).
- Disconnect the accelerator control cable and the cruise control cable from the cable bracket. Disconnect the cruise control cable engine-end fitting from the stud on the throttle lever, if equipped. Disconnect the accelerator control cable and the cruise control cable from the throttle body.
- Remove the upper engine wire harness retainer nut. See Fig 1. Disconnect the evaporative emission (EVAP) purge valve harness connector. Reposition the upper engine wire harness aside. Mark the electrical connectors to their corresponding gasoline injectors to ensure correct sequential injector firing order after reassembly.
- Pull the Connector Position Assurance (CPA) of the injector connector up. Pull the tab (1) on the injector connector in. See Fig 2. While pushing the tab on the injector connector in, release the CPA (2). Disconnect the fuel injector electrical connector. Repeat for each injector connector.
- Disconnect the fuel feed and return pipes (1 and 2) from the fuel rail. See Fig 3. Disconnect the fuel pressure regulator vacuum line. Loosen the crossover tube to right fuel rail retainer screw. Remove the right fuel rail attaching nuts. Remove the left fuel rail attaching nuts.
- 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. Remove the gasoline and CNG fuel rails as an assembly.
- Remove the crossover tube rail retainer screws. Remove the crossover tube. Remove the injector (7) retainer bolt and clip (10). See Figure. Remove the injector from the fuel rail with a pulling a twisting motion. Remove the fuel injector adaptor (9) from the fuel injector. Repeat for the remaining fuel injectors.
- Remove the fuel rail pressure sensor (13) and discard the "O" ring. See FUEL RAIL PRESSURE SENSOR under SENSORS & SWITCHES.
- Remove the fuel rail temperature sensor (11) and discard the "O" ring. See FUEL RAIL TEMPERATURE SENSOR under SENSORS & SWITCHES. If necessary, remove the low pressure lock-off solenoid (2) mounting screws (1) and discard the "O" ring (12).
NOTE:
Identify the injector connectors to their corresponding engine cylinder to ensure correct sequential injector firing order after reassembly.
NOTE:
When disconnecting Multec 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered useless.
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.