GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Fuel Injection Fuel Rail Assembly Replacement - Bank 2

Removal Procedure

    Object Number: 687021 Size: SH
  1. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Reposition the positive crankcase ventilation (PCV) hose clamp.
  5. Remove the PCV hose.
  6. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  7. Remove the fuel filter. Refer to Fuel Filter Replacement
  8. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement .

    9. Object Number: 660438 Size: SH
  9. Disconnect the fuel feed rear pipe from the junction block (1).

    10. Object Number: 660502 Size: SH
  10. Remove the fuel injector feed pipe retainer bolts and retainers.
  11. Remove the fuel injector pipes.

    12. Object Number: 660459 Size: SH
  12. Remove the fuel rail bolts and rail.

Installation Procedure

    Object Number: 660459 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  1. Install the fuel rail and bolts.

    2. Tighten
    Tighten the bolts to 26 N·m (19 lb ft).


    Object Number: 660502 Size: SH
  2. Install the fuel injector pipes.

    3. Tighten
    Tighten the fittings to 41 N·m (30 lb ft).

  3. Install the fuel injector feed pipe retainers and bolts.

    4. Tighten
    Tighten the bolts to 4 N·m (35 lb in).


    Object Number: 660438 Size: SH
  4. Connect the fuel feed rear pipe at the end of the fuel rail (1).

    5. Tighten
    Tighten the lines to 44 N·m (32 lb ft).

  5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  6. Install the fuel filter. Refer to Fuel Filter Replacement .
  7. Connect the fuel injection control module. Refer to Fuel Injector Control Module Replacement .

    8. Object Number: 687021 Size: SH
  8. Install the PCV hose.
  9. Reposition the PCV hose clamp.
  10. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  11. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  12. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Replace all hold down ties.
  14. Start the engine and check for leaks or noises.
  15. After the engine warms up, refill the coolant reservoir.