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 Injection Fuel Rail Assembly Replacement - Bank 1

Removal Procedure

    Object Number: 1335454 Size: SH
  1. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the air cleaner . Refer to Air Cleaner Replacement .
  3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  4. Remove the fuel injection control module (FICM). Refer to Fuel Injector Control Module Replacement .
  5. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  6. Reposition the right positive crankcase ventilation (PCV) hose clamp at the resonator tee.
  7. Remove the right PCV hose from the tee.

    8. Object Number: 1335456 Size: SH
  8. Remove the right PCV pipe bolt.

    9. Object Number: 1335462 Size: SH
  9. Remove the right PCV pipe.

    10. Object Number: 1335586 Size: SH
  10. Disconnect the fuel rail balance pipe from the fuel rails.
  11. Remove the fuel rail balance pipe bolts.
  12. Remove the fuel rail balance pipe.

    13. Object Number: 1335614 Size: SH
  13. Remove the fuel injector pipes.

    14. Object Number: 1335617 Size: SH
  14. Remove the fuel rail bolts.
  15. Remove the fuel rail.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1335617 Size: SH
  1. Install the fuel rail.
  2. Install the fuel rail bolts.

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


    Object Number: 1335614 Size: SH
  3. Install the fuel injector pipes.

    4. Tighten
    Tighten the fittings to 41 N·m (30 lb ft).


    Object Number: 1335586 Size: SH
  4. Install the fuel rail balance pipe.
  5. Connect the fuel rail balance pipe to the fuel rails.

    6. Tighten
    Tighten the fittings to 41 N·m (30 lb ft).

  6. Install the fuel rail balance pipe bolts.

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


    Object Number: 1335462 Size: SH
  7. Install the right PCV pipe.

    8. Object Number: 1335456 Size: SH
  8. Install the right PCV pipe bolt.

    9. Tighten
    Tighten the bolt to 18 N·m (13 lb ft).


    Object Number: 1335454 Size: SH
  9. Install the right PCV hose to the tee.
  10. Position the right PCV hose clamp at the resonator tee.
  11. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  12. Install the FICM. Refer to Fuel Injector Control Module Replacement .
  13. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  14. Install the air cleaner . Refer to Air Cleaner Replacement .
  15. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  16. Prime the fuel system. Refer to Fuel System Priming .
  17. Start the engine. If the engine stalls, repeat the above step.
  18. Once the engine starts, inspect for fuel leaks.