GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L (LLY) 🢒 Fuel Return Pipe Replacement

Removal Procedure
  1. Remove the air cleaner. Refer to Air Cleaner Replacement .

    2. Object Number: 1387822 Size: SH
  2. Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
  3. Remove the water outlet. Refer to Water Outlet Tube Replacement in Engine Cooling.
  4. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  5. Reposition the fuel return line hose clamps (1).
  6. Remove the fuel return line hoses from the return line.

    7. Object Number: 1387823 Size: SH
  7. Remove the fuel return line clamp bolts (1).
  8. Reposition the fuel return line hose clamp (3) from the fuel rail.
  9. Remove the fuel return line hose from the fuel rail.
  10. Remove the fuel return line (2).

Removal Procedure

    Object Number: 1387823 Size: SH
  1. Install the fuel return line (2).
  2. Install the fuel return line hose to the fuel rail.

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

  3. Position the fuel return line hose clamp (3) at the fuel rail.
  4. Install the fuel return line clamp bolts (1).

    5. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1387822 Size: SH
  5. Install the fuel return line hoses to the return line.
  6. Position the fuel return line hose clamps (1).
  7. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  8. Install the water outlet. Refer to Water Outlet Tube Replacement in Engine Cooling.
  9. Install the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
  10. Install the air cleaner. Refer to Air Cleaner Replacement .
  11. Prime the fuel system. Refer to Fuel System Priming .
  12. Start the engine. If the engine stalls, repeat the above step.
  13. Once the engine starts, inspect for fuel leaks.