GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Injection Fuel Rail Assembly Replacement - Bank 1

Removal Procedure

    Object Number: 1866599 Size: SH
  1. Remove the engine cover. Refer to Engine Cover Replacement.
  2. Remove the generator. Refer to Generator Replacement.
  3. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
  4. Remove the turbocharger coolant outlet hose/pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement.
  5. Disconnect the fuel rail fuel feed pipe fitting (1) from the fuel rail.
  6. Disconnect the engine wiring harness electrical connector from the fuel rail pressure sensor wiring harness electrical connector (2).
  7. Remove the fuel rail pressure sensor wiring harness electrical connector clip from the bracket.
  8. Remove the fuel rail pressure sensor wiring harness clip (3) from the bracket.

    9. Object Number: 1335614 Size: SH
  9. Remove the fuel injector pipes.

    10. Object Number: 1866601 Size: SH
  10. Remove the fuel rail bolts (1).
  11. Remove the fuel rail.
  12. Disconnect the fuel rail pressure sensor wiring harness from the sensor, if required.
  13. Remove the fuel rail pressure sensor from the fuel rail, if required.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1866601 Size: SH
  1. Install the fuel rail pressure sensor to the fuel rail, if required.

    2. Tighten
    Tighten the sensor to 70 N·m (52 lb ft).

  2. Connect the fuel rail pressure sensor wiring harness to the sensor, if required.
  3. Position the fuel rail.
  4. Install the fuel rail bolts (1).

    5. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1335614 Size: SH
  5. Install the fuel injector pipes.

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


    Object Number: 1866599 Size: SH
  6. Install the fuel rail pressure sensor wiring harness clip (3) from the bracket.
  7. Install the fuel rail pressure sensor wiring harness electrical connector clip to the bracket.
  8. Connect the engine wiring harness electrical connector to the fuel rail pressure sensor wiring harness electrical connector (2).
  9. Connect the fuel rail fuel feed pipe fitting (1) to the fuel rail.

    10. Tighten
    Tighten the fitting to 41 N·m (30 lb ft).

  10. Install the turbocharger coolant outlet hose/pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement.
  11. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
  12. Install the generator. Refer to Generator Replacement.
  13. Install the engine cover. Refer to Engine Cover Replacement.
  14. Prime the fuel system. Refer to Fuel System Priming.
  15. Start the engine. If the engine stalls, repeat the above step.
  16. Once the engine starts, inspect for fuel leaks.