GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 GMC C Sierra - 2WD 🢒 Engine 🢒 Engine Electrical 🢒 Fuel Injection Fuel Rail Assembly Replacement - Bank 2

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 664853 Size: SH
  1. Disconnect the negative battery cables from both batteries.
  2. Drain the coolant. Refer to Cooling System Draining and Filling .
  3. Remove the upper radiator hose and two hose clamps.
  4. Remove the bolt holding the positive battery cable junction box and bracket and move it out of the way.

    5. Important: Tape the turbo to keep foreign material out.

  5. Remove the turbo charged air outlet hose.

    6. Object Number: 786978 Size: SH
  6. Disconnect the 3 glow plug relay connectors (1, 2, 3).
  7. Remove the glow plug bracket.

    8. Object Number: 674653 Size: SH
  8. Disconnect both 40 pin and 24 pin engine connectors.
  9. Remove the engine connector bracket and set aside.
  10. Disconnect the fuel in-line and return lines.
  11. Remove the L-bracket holding the fuel lines.

    12. Object Number: 687021 Size: SH
  12. Remove the positive crankcase ventilation (PCV) hose and clamp and move out of the way.
  13. Remove the water pipe outlet from the thermostat housing.
  14. Remove the serpentine belt.

    15. Object Number: 652573 Size: SH
  15. Remove the bolts holding the air conditioning compressor and flip the unit aside.

    16. Object Number: 660448 Size: SH
  16. Remove the line from the junction block to the injection pump.

    17. Object Number: 660446 Size: SH
  17. Loosen the high pressure line (1) at the back end of the fuel rail and remove.

    18. Object Number: 660449 Size: SH
  18. Remove the junction block assembly.

    19. Object Number: 660451 Size: SH
  19. Loosen the high pressure injection lines at the four injectors first.
  20. Loosen the high pressure injection lines at the four fittings on the fuel rail
  21. Mark the high pressure injection lines in order and remove them.

    22. Object Number: 660456 Size: SH
  22. Remove the three bolts holding the fuel rail and remove.

Installation Procedure

    Object Number: 660456 Size: SH
  1. Install the new fuel rail and bolts.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 660451 Size: SH
  2. Connect the high pressure lines between the fuel rail and injectors.

    3. Tighten
    Tighten the high pressure lines to 44 N·m (32 lb ft).


    Object Number: 660449 Size: SH
  3. Install the junction block assembly.

    4. Object Number: 660446 Size: SH
  4. Connect the high pressure line (1) to the back end of the fuel rail.

    5. Tighten
    Tighten the fuel rail bolts to 26 N·m (19 lb ft).


    Object Number: 660448 Size: SH
  5. Install the line from the junction block to the injection pump.

    6. Object Number: 652573 Size: SH
  6. Install the bolts holding the air conditioning compressor.
  7. Install drive belt. Refer to Drive Belt Replacement .
  8. Install the water outlet pipe to thermostat housing.

    9. Object Number: 687021 Size: SH
  9. Attach the PCV hose and clamp.
  10. Install the L-bracket holding the fuel lines.
  11. Connect the fuel lines.
  12. Install the glow plug bracket.
  13. Install the glow plug relay. Refer to Glow Plug Relay Replacement .

    14. Object Number: 786978 Size: SH
  14. Connect the connectors to the glow plug relays (1, 2, 3).

    15. Object Number: 664853 Size: SH
  15. Attach the turbo hose and clamp at the turbo to the intercooler.
  16. Install the bolt holding the positive battery cable junction box and bracket.
  17. Replace the upper radiator hose and two hose clamps.
  18. Replace the coolant. Refer to Cooling System Draining and Filling .
  19. Connect the negative battery cables to both batteries.
  20. Replace all hold down ties.
  21. Start the engine and check for leaks or noises.
  22. After the engine warms up, refill the coolant reservoir to the proper level.