GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 GMC C Sierra - 2WD 🢒 Engine 🢒 Engine Controls - 6.6L (LB7) 🢒 Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump

Removal Procedure

    Object Number: 877275 Size: SH
  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. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Loosen the charged air cooler outlet duct to intake clamp (1).

    5. 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.

  5. Remove the charged air cooler outlet duct.

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

    7. 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.

  7. Remove the charged air cooler inlet duct from the turbocharger.
  8. Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
  9. Remove the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.

    10. Object Number: 791993 Size: SH
  10. Reposition the fuel hose clamps.
  11. Remove the fuel hose from the fuel return rear pipe.
  12. Remove the fuel hose from the fuel injection pump.

Installation Procedure

    Object Number: 791993 Size: SH
  1. Install the fuel hose to the fuel injection pump.
  2. Install the fuel hose to the fuel return rear pipe.
  3. Position the fuel hose clamps.
  4. Install the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.

    5. Object Number: 877281 Size: SH
  5. Install the charged air cooler inlet duct to the turbocharger.

    6. 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.

  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance.

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


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

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

  11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.