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Home >> Chevrolet >> 2005 >> Avalanche 2500 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 8.1L - Introduction >> Repair Instructions >> Fuel Rail Assembly Replacement >> Removal Procedure
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Removal Procedure

IMPORTANT: An eight digit identification number is located on the fuel rail. Refer to this number if servicing, or part replacement is required.
    Fig 1: View Of Generator, Injector Harness, Ignition Coil Harness, ETC & Purge Valve Solenoid Electrical Connectors
    GM1235689Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical - 8.1L.
  3. Disconnect the generator electrical connector (2).
  4. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
  5. Disconnect the electronic throttle control (ETC) electrical connector (5).
  6. Remove the engine harness bolt and studs.
  7. Reposition the engine harness to the drivers side of the engine compartment.
    8. Fig 2: Identifying Lock Release
    GM372749Courtesy of GENERAL MOTORS CORP.
  8. Identify the fuel injector connectors to their corresponding injectors in order to ensure correct sequential injector firing order after reassembly.
  9. Pull the top portion (2) of the connector up. Do not pull the top portion of the connector past the top of the white portion (1).
    10. Fig 3: Disconnecting Fuel Injector Electrical Connectors
    GM372753Courtesy of GENERAL MOTORS CORP.
  10. Push the tab (1) on the lower side of the connector in order to release the connector from the injector.
  11. Repeat step 12 and step 13 for each injector connector.
    12. Fig 4: View Of Fuel Feed Pipe & EVAP Canister Purge Pipe
    GM1238587Courtesy of GENERAL MOTORS CORP.
    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.
  12. Disconnect the fuel feed (1) line from the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    13. Fig 5: View Of Fuel Injection Rail
    GM1198692Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Before removal, clean the fuel rail with a spray type engine cleaner such as, GM X-30A or equivalent, if necessary. Follow the package instructions. Do not soak the fuel rails in liquid cleaning solvent.
  13. Remove the fuel rail studs.
  14. Remove the fuel rail.
    15. Fig 6: View Of Fuel Injector, Clip & O-Rings
    GM351185Courtesy of GENERAL MOTORS CORP.
  15. Remove and discard the fuel injector lower O-ring seals (4) from the spray tip end of each injector (3).
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