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 2

Removal Procedure
  1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  2. Remove the air cleaner . Refer to Air Cleaner Replacement .
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  4. Remove the fuel filter and element housing. Refer to Fuel Filter Assembly Replacement .
  5. Remove the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.

    6. Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.

  6. Remove the charged air cooler inlet pipe from the turbocharger. Refer to Charged Air Cooler Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).

    7. Object Number: 1378748 Size: SH
  7. Disconnect the fuel feed and return line quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service .
  8. Remove the fuel line bracket nut.
  9. Remove the fuel line bracket from the stud.

    10. Object Number: 1335454 Size: SH
  10. Reposition the left positive crankcase ventilation (PCV) hose clamp at the resonator tee.
  11. Remove the left PCV hose from the tee.

    12. Object Number: 1335460 Size: SH
  12. Remove the left PCV hose/pipe bolt.

    13. Object Number: 1335462 Size: SH
  13. Remove the left PCV hose/pipe.

    14. Object Number: 769156 Size: SH
  14. Remove the air conditioning (A/C) compressor bolts (1) and the A/C compressor (3) from the bracket (2).
  15. Reposition the A/C compressor aside.

    16. Object Number: 1335584 Size: SH
  16. Remove the banjo bolt and washer from the fuel injection control module.
  17. Remove the fuel feed pipe nuts/bolts.
  18. Remove the fuel feed pipe.

    19. Object Number: 1335586 Size: SH
  19. Disconnect the fuel rail balance pipe from the fuel rails.
  20. Remove the fuel rail balance pipe bolts.
  21. Remove the fuel rail balance pipe.

    22. Object Number: 1335588 Size: SH
  22. Disconnect the fuel injector return hose from the distribution block line.

    23. Object Number: 1335595 Size: SH
  23. Reposition the distribution block hose clamps at the injection pump.
  24. Remove the fuel hoses from the distribution block.

    25. Object Number: 1335596 Size: SH
  25. Reposition the distribution block hose clamp at the rear of the left fuel rail.
  26. Remove the fuel hose from the fuel rail.
  27. Remove the distribution block fuel line clip bolts.
  28. Remove the distribution block and lines.

    29. Object Number: 1335598 Size: SH
  29. Remove the fuel pipe bracket bolts.
  30. Remove the fuel pipe bracket.

    31. Object Number: 1335603 Size: SH
  31. Disconnect the fuel inlet pipe from the fuel rail.
  32. Disconnect the fuel inlet pipe from the injection pump.
  33. Remove the inlet fuel pipe.

    34. Object Number: 1335608 Size: SH
  34. Remove the fuel injector pipes.

    35. Object Number: 1335616 Size: SH
  35. Remove the fuel rail bolts.
  36. Remove the fuel rail and bracket.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1335616 Size: SH
  1. Install the fuel rail and bracket.
  2. Install the fuel rail bolts.

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


    Object Number: 1335608 Size: SH
  3. Install the fuel injector pipes.

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


    Object Number: 1335603 Size: SH
  4. Remove the inlet fuel pipe.
  5. Connect the fuel inlet pipe to the injection pump.
  6. Connect the fuel inlet pipe to the fuel rail.

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


    Object Number: 1335598 Size: SH
  7. Install the fuel pipe bracket.
  8. Install the fuel pipe bracket bolts.

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


    Object Number: 1335596 Size: SH
  9. Install the distribution block and lines.
  10. Install the distribution block fuel line clip bolts.

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

  11. Install the fuel hose to the fuel rail.
  12. Position the distribution block hose clamp at the rear of the left fuel rail.

    13. Object Number: 1335595 Size: SH
  13. Install the fuel hoses to the distribution block.
  14. Position the distribution block hose clamps at the injection pump.

    15. Object Number: 1335588 Size: SH
  15. Connect the fuel injector return hose to the distribution block line.

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

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

  18. Install the fuel rail balance pipe bolts.

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


    Object Number: 1335584 Size: SH
  19. Install the fuel feed pipe.
  20. Install the fuel feed pipe nut/bolt.

    21. Tighten
    Tighten the nut/bolt to 25 N·m (18 lb ft).

  21. Install the banjo bolt and washer to the fuel injection control module.

    22. Tighten
    Tighten the bolt to 40 N·m (29 lb ft).


    Object Number: 769156 Size: SH
  22. Position the A/C compressor (3) onto the bracket (2).
  23. Install the A/C compressor bolts (1).

    24. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 1335462 Size: SH
  24. Install the left PCV hose/pipe.

    25. Object Number: 1335460 Size: SH
  25. Install the left PCV hose/pipe bolt.

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


    Object Number: 1335454 Size: SH
  26. Install the left PCV hose to the tee.
  27. Position the left PCV hose clamp at the resonator tee.
  28. Install the fuel line bracket to the stud.
  29. Install the fuel line bracket nut.

    30. Tighten
    Tighten the nut to 21 N·m (15 lb ft).

  30. Connect the fuel feed and return line quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service .
  31. Remove the tape from the turbocharger openings.

    32. Important: Lubricate the end of the duct prior to installation.

  32. Install the charged air cooler inlet pipe to the turbocharger. Refer to Charged Air Cooler Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
  33. Install the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
  34. Install the fuel filter and element housing. Refer to Fuel Filter Assembly Replacement .
  35. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  36. Install the air cleaner . Refer to Air Cleaner Replacement .
  37. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  38. Prime the fuel system. Refer to Fuel System Priming .
  39. Start the engine. If the engine stalls, repeat the above step.
  40. Once the engine starts, inspect for fuel leaks.