GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2008 🢒 Sierra - 2WD 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Return Pipe Replacement

Removal Procedure

    Object Number: 1872010 Size: SH
  1. Remove the water outlet. Refer to Water Outlet Tube Replacement .
  2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement .
  3. Remove the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement .
  4. Remove the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement .
  5. Reposition the fuel hose clamp (1) at the fuel return pipe.

    6. Object Number: 1872011 Size: SH
  6. Remove the fuel hose (1) from the return pipe.

    7. Object Number: 1872348 Size: SH

    Important: Engine wiring harness shown removed for clarity.

  7. Reposition the fuel return hose clamp (2) at the fuel return pipe.

    8. Object Number: 1872344 Size: SH
  8. Remove the fuel return pipe clip bolt (2) and clip.
  9. Remove the fuel return pipe clamp bolt (1) and bracket.

    10. Object Number: 1872345 Size: SH
  10. Reposition the fuel return hose clamp (1) at the return pipe.
  11. Remove the fuel return hose from the return pipe.
  12. Remove the fuel return pipe clamp bolt (2) and clamp.
  13. Disconnect the fuel injection fuel feed pipe (3) from the fuel return pipe.

    14. Object Number: 1872346 Size: SH

    Important: Note the routing of the fuel return pipe prior to removal.

  14. Remove the fuel return pipe from the fuel return hose and the vehicle.

Installation Procedure

    Object Number: 1872346 Size: SH

    Important: Ensure to route the fuel return pipe under the wiring harness and noted during removal.

  1. Position and install the fuel return pipe to the vehicle and the fuel return hose.

    2. Object Number: 1872345 Size: SH
  2. Connect the fuel injection fuel feed pipe (3) to the fuel return pipe.

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

  3. Position and install the fuel return pipe clamp and bolt (2).

    4. Tighten
    Tighten the bolt to 24 N·m (18 lb ft).

  4. Install the fuel return hose to the return pipe.
  5. Position the fuel return hose clamp (1) at the return pipe.

    6. Object Number: 1872344 Size: SH
  6. Install the fuel return pipe bracket, clamp, and bolt (1).

    7. Tighten
    Tighten the bolt to 24 N·m (18 lb ft).

  7. Install the fuel return pipe clip and bolt (2).

    8. Tighten
    Tighten the bolt to 24 N·m (18 lb ft).


    Object Number: 1872348 Size: SH
  8. Position the fuel return hose clamp (2) at the fuel return pipe.

    9. Object Number: 1872011 Size: SH
  9. Install the fuel hose (1) to the return pipe.

    10. Object Number: 1872010 Size: SH
  10. Position the fuel hose clamp (1) at the fuel return pipe.
  11. Install the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement .
  12. Install the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement .
  13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement .
  14. Install the water outlet. Refer to Water Outlet Tube Replacement .
  15. Prime the fuel system. Refer to Fuel System Priming .
  16. Start the engine. If the engine stalls, repeat the above step.
  17. Once the engine starts, inspect for fuel leaks.