GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Crew) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Fuel Return Pipe Replacement

Removal Procedure
  1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 664851 Size: SH
  3. Remove the right turbo charged air outlet hose.

    4. Object Number: 664853 Size: SH
  4. Remove the left turbo charged air outlet hose.
  5. Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .

    6. Object Number: 791983 Size: SH
  6. Remove the fuel feed line (1).

    7. Object Number: 791996 Size: SH
  7. Remove the fuel injection pump to fuel feed block hose.

    8. Object Number: 660433 Size: SH
  8. Remove the glow plug controller. Refer to Glow Plug Relay Replacement .

    9. Object Number: 660446 Size: SH
  9. Remove the bolts from cylinder head (2), leak-off block and junction block.

    10. Object Number: 755230 Size: SH
  10. Remove the fuel line retainers.

    11. Object Number: 791904 Size: SH
  11. Remove the fuel return line assembly.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 791904 Size: SH

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

  1. Install the fuel return line assembly.

    2. Tighten
    Tighten the bolt to 27 N·m (19 lb ft).


    Object Number: 755230 Size: SH
  2. Install the fuel line retainers.

    3. Tighten
    Tighten the bolt to 16 N·m (11 lb ft).


    Object Number: 660446 Size: SH
  3. Install the bolts to the cylinder head (2), leak-off block and junction block.

    4. Tighten
    Tighten the bolts to 15 N·m (11 lb ft).


    Object Number: 660433 Size: SH
  4. Install the glow plug controller. Refer to Glow Plug Relay Replacement .

    5. Object Number: 791996 Size: SH
  5. Install the fuel injection pump to fuel feed block hose.

    6. Object Number: 791983 Size: SH
  6. Install the fuel feed line (1).

    7. Tighten
    Tighten the fuel feed line nuts to 8 N·m (70 lb in).


    Object Number: 664853 Size: SH
  7. Install the engine wiring harness assembly. Refer to Engine Wiring Harness Assembly Replacement .
  8. Install the left turbo charged air outlet hose.

    9. Object Number: 664851 Size: SH
  9. Install the right turbo charged air outlet hose.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  11. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.