GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Fuel Return Pipe Connector Replacement

Removal Procedure

    Object Number: 877275 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Loosen the charged air cooler outlet duct clamp (1).

    4. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  4. Remove the charged air cooler outlet duct.

    5. Object Number: 877281 Size: SH
  5. Loosen the charged air cooler inlet duct to turbocharger clamp (1).

    6. Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  6. Remove the charged air cooler inlet duct from the turbocharger.
  7. Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .

    8. Object Number: 660425 Size: SH
  8. Remove the heater pipe bolt and pipe.

    9. Object Number: 791983 Size: SH
  9. Remove the fuel feed front pipe bracket nut.
  10. Remove the fuel feed front pipe (1).
  11. Remove the generator. Refer to Generator Replacement in Engine Electrical.

    12. Object Number: 791986 Size: SH
  12. Reposition the fuel hose clamps.
  13. Remove the fuel feed hoses from fuel feed block (1).
  14. Remove the fuel feed junction block bolt/nut and remove the feed block (1).
  15. Remove the fuel return pipe to cylinder head bolt.
  16. Remove the fuel return pipe (2).

Installation Procedure

    Object Number: 791986 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.

    Important: Always install new fuel line gaskets when servicing fuel lines.

  1. Install the fuel return pipe (2).
  2. Install the fuel return pipe to cylinder head bolt.

    3. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).

  3. Install the fuel feed junction block (1) and bolt/nut.

    4. Tighten
    Tighten the bolt/nut to 25 N·m (18 lb ft).

  4. Install the fuel feed hoses to fuel feed block (1).
  5. Reposition the fuel hose clamps.
  6. Install the generator. Refer to Generator Replacement in Engine Electrical.

    7. Object Number: 791983 Size: SH
  7. Install the fuel feed front pipe (1).
  8. Install the fuel feed front pipe bracket nut.

    9. Tighten
    Tighten the nut to 8 N·m (70 lb in).


    Object Number: 660425 Size: SH
  9. Install the heater pipe and bolt.

    10. Tighten
    Tighten the bolt to 20 N·m (14 lb ft).


    Object Number: 877281 Size: SH
  10. Install the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
  11. Install the charged air cooler inlet duct to turbocharger.
  12. Align the mark on the duct (2) with the mark on the turbocharger.
  13. Position the clamp (1) as shown for proper clearance.

    14. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 877275 Size: SH
  14. Install the charged air cooler outlet duct to the intake.
  15. Align the mark on the duct (3) with the mark on the turbocharger.
  16. Position the clamp (1) as shown for proper clearance.

    17. Tighten
    Tighten the clamp to 6 N·m (53 lb in).

  17. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  18. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.