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Home › Chevrolet › 2018 › Suburban 3500 HD LS › Repair and Diagnosis › Engine Performance › Engine Control Systems › Engine Controls And Fuel - 6.0L (L96) - Repair Instructions › Repair Instructions › Fuel Injector Replacement › Removal Procedure

Removal Procedure

CAUTION:

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.

NOTE:
  • An 8-digit identification number is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required.
  • The engine oil may be contaminated with fuel if the fuel injectors are leaking.
    Fig 1: Engine Harness Retainer Nut And Electrical Connectors
    GM1696891Courtesy of GENERAL MOTORS COMPANY
  1. Remove the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement 
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (Without CH-48027) .
  3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Dual Battery)Battery Negative Cable Disconnection and Connection (Single Battery)
  4. Remove the engine wiring harness bracket nut (1).
  5. Disconnect the engine wiring harness electrical connector (3) from the generator.
  6. Disconnect the generator battery control wiring harness cable. Refer to Generator Replacement (L96)
  7. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor.
    8. Fig 2: CPA Retainer, Engine Harness Electrical Connectors And Harness Clips
    GM1696893Courtesy of GENERAL MOTORS COMPANY
  8. Disconnect the engine wiring harness electrical connector (3) from the electronic throttle control.
    9. Fig 3: CPA Retainer, Electrical Connectors And Engine Harness Clips
    GM1696892Courtesy of GENERAL MOTORS COMPANY
  9. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors, perform the following:
    1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    2. Pull the CPA retainer on the connector up 1 click.
    3. Push the tab on the connector in.
    4. Disconnect the fuel injector electrical connector.
    10. Fig 4: CPA Retainer, Engine Harness Electrical Connectors And Harness Clips
    GM1696893Courtesy of GENERAL MOTORS COMPANY
  10. Disconnect the engine wiring harness electrical connectors (7) from the fuel injectors, perform the following:
    1. Mark the connectors to their corresponding injectors to ensure correct reassembly.
    2. Pull the CPA retainer on the connector up 1 click.
    3. Push the tab on the connector in.
    4. Disconnect the fuel injector electrical connector.
    11. Fig 5: Negative Battery Cable Terminal, Engine Wiring Harness Ground Terminal And Stud
    GM1699543Courtesy of GENERAL MOTORS COMPANY
  11. Remove the negative battery cable stud (1) from the right cylinder head.
  12. Remove the negative battery cable terminal (2) and engine wiring harness ground terminal (3) from the cylinder head.
    13. Fig 6: Engine Wiring Harness, Clip, Bolt And Connector
    GM1696914Courtesy of GENERAL MOTORS COMPANY
  13. Remove the engine wiring harness clip bolt (3) from the generator bracket.
  14. Gather the branches of the engine wiring harness and reposition them aside.
    15. Fig 7: PCV Hose
    GM1696791Courtesy of GENERAL MOTORS COMPANY
  15. Remove the positive crankcase ventilation (PCV) hose.
    16. Fig 8: Fuel Feed Pipe, EVAP Canister Purge Tube And Quick Connect Fitting
    GM1696917Courtesy of GENERAL MOTORS COMPANY
  16. Disconnect the chassis fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  17. Disconnect the engine wiring harness electrical connector from the evaporative emission (EVAP) purge solenoid.
    18. Fig 9: EVAP Tube And Purge Solenoid
    GM1697062Courtesy of GENERAL MOTORS COMPANY
  18. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service .
  19. Disconnect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  20. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail.
  21. Remove the EVAP tube and purge solenoid.
    22. Fig 10: Fuel Rail And Bolts
    GM1697066Courtesy of GENERAL MOTORS COMPANY
  22. Remove the fuel rail bolts.
    23. CAUTION:
    • 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.
    NOTE:
    • 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 rail in liquid cleaning solvent.
    • Lift evenly on both sides of the fuel rail until all injectors are removed from their bores.
  23. Remove the fuel rail assembly.
    24. Fig 11: Fuel Injector Components
    GM1706106Courtesy of GENERAL MOTORS COMPANY
  24. Remove the fuel injector retainers (1).
  25. Remove the fuel injectors (3) from the fuel rail.
  26. Remove and discard the fuel injector upper and lower O-ring seals (2 and 4).
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