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Home >> Chevrolet >> 2001 >> C3500 HD 8.1 G, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 8.1L - Repair Instructions >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Removal Procedure
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Removal Procedure

    IMPORTANT:

    An eight digit identification number is located on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief  in engine controls.
  2. Before removal, clean the fuel rail assembly with a spray type engine cleaner, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak fuel rails in liquid cleaning solvent.
    3. Fig 1: Intake Manifold Sight Shield, Bolts & Retainer
    GM665445Courtesy of GENERAL MOTORS COMPANY
  3. Remove the engine sight shield bracket (1) nuts and bracket.
    4. Fig 2: View Of Front Of Engine
    GM665449Courtesy of GENERAL MOTORS COMPANY
  4. Disconnect the generator harness connector (1).
  5. Disconnect the (EVAP) canister purge valve harness connector (4).
  6. Disconnect the throttle position (TP) sensor harness connector (2).
  7. Disconnect the electronic throttle control (ETC) harness connector (3).
  8. Remove the upper engine wire harness bracket studs and position the upper engine wire harness aside.
  9. Remove the Secondary Air Injection (AIR) crossover pipe if applicable, Refer to Secondary Air Injection Crossover Pipe/Hose Replacement .
    10. Fig 3: Identifying Lock Release
    GM372749Courtesy of GENERAL MOTORS COMPANY
  10. Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly.
  11. Pull the top portion (2) of the injector connector up. Do not pull the top portion of the connector past the top of the white portion (1).
    12. Fig 4: Fuel Injector Electrical Connectors Lock Tab
    GM372753Courtesy of GENERAL MOTORS COMPANY
  12. Push the tab (1) on the lower side of the injector connector in order to release the connector from the injector.
  13. Repeat step 12 and step 13 for each injector connector.
    14. Fig 5: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS COMPANY
  14. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail.
    15. Fig 6: View Of Fuel Pressure Regulator Vacuum Line
    GM665447Courtesy of GENERAL MOTORS COMPANY
  15. Disconnect the fuel pressure regulator vacuum line (1).
    16. Fig 7: View Of Fuel Rail Assembly
    GM665443Courtesy of GENERAL MOTORS COMPANY
  16. Remove the fuel rail attaching bolts (3).
  17. Remove the fuel rail assembly (1).
    18. Fig 8: View Of Fuel Injector, Clip & O-Rings
    GM351185Courtesy of GENERAL MOTORS COMPANY
  18. Remove the injector lower O-ring seal (4) from the spray tip end of each injector (3).
  19. Discard the O-ring seals.
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