GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Mechanical - 6.6L (LB7) 🢒 Fuel Injection Fuel Rail Assembly Replacement - Bank 2

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cables from both batteries.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

    3. Important: Cover the air intake pipe with tape to keep foreign material out.

  3. Remove the air cleaner layer. Refer to Air Cleaner Replacement .

    4. Object Number: 664851 Size: SH
  4. Remove the right side charged air outlet hose and clamps.

    5. Object Number: 687021 Size: SH
  5. Remove the positive crankcase ventilation (PCV) hose and clamp.
  6. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  7. Remove the fuel filter. Refer to Fuel Filter Replacement .

    8. Object Number: 660438 Size: SH
  8. Disconnect the high pressure fuel rail line coming from the junction block (1).

    9. Object Number: 660502 Size: SH
  9. Loosen the high pressure injection lines at the four injectors.
  10. Loosen the high pressure lines injection at the four fittings on the fuel rail.
  11. Mark the high pressure injection lines in order and remove them.

    12. Object Number: 660459 Size: SH
  12. Remove the three bolts holding the fuel rail.

Installation Procedure

    Object Number: 660459 Size: SH
  1. Install the new fuel rail and bolts.

    2. Object Number: 660502 Size: SH

    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.

  2. Connect the high pressure lines between the fuel rail and injectors.

    3. Tighten
    Tighten the high pressure lines to 44 N·m (33 lb ft).

  3. Attach the high pressure line to the back of the fuel rail

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


    Object Number: 660438 Size: SH
  4. Connect the high pressure fuel line at the end of the fuel rail (1).
  5. Install the fuel filter. Refer to Fuel Filter Replacement .
  6. Connect the fuel injection control module. Refer to Fuel Injector Control Module Replacement .

    7. Object Number: 687021 Size: SH
  7. Attach the PCV hose and clamp.

    8. Object Number: 664851 Size: SH
  8. Attach the charged air outlet hose and clamp.
  9. Install the bolt holding the positive battery cable junction box and bracket.
  10. Replace the upper radiator hose and the two hose clamps.
  11. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  12. Connect the negative battery cables to both batteries.
  13. Replace all hold down ties.
  14. Check for fuel leaks or noises. Refer to Fuel System Diagnosis
  15. Install the air cleaner layer. Refer to Air Cleaner Replacement .
  16. After the engine warms up, refill the coolant reservoir.