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

Removal Procedure

    Object Number: 1866354 Size: SH
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  2. Remove the water outlet. Refer to Water Outlet Tube Replacement.
  3. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
  4. Remove the fuel return pipe clamp bolt (1) and upper clamp.
  5. Reposition the fuel return hose clamps (2).
  6. Remove the fuel return pipe from the fuel return hoses.
  7. Remove the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement.

    8. Object Number: 1866355 Size: SH
  8. Remove the engine wiring harness rear bracket bolt and bracket.

    9. Object Number: 1866356 Size: SH
  9. Remove the fuel return pipe clamp bolt (1) and upper clamp.
  10. Reposition the fuel return hose clamp (2) at the fuel rail.
  11. Remove the fuel return hose from the fuel rail.
  12. Disconnect the fuel injection fuel return pipe fitting (3) from the fuel return pipe.

    13. Object Number: 1866357 Size: SH
  13. Remove the fuel return pipe from the engine and pipe clamp if equipped.

Installation Procedure

    Object Number: 1866357 Size: SH
  1. Install the fuel return pipe to the engine.

    2. Object Number: 1866356 Size: SH
  2. Connect the fuel injection fuel return pipe fitting (3) to the fuel return pipe.
  3. Install the fuel return hose to the fuel rail.
  4. Position the fuel return hose clamp (2) at the fuel rail.

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the fuel return pipe upper clamp and bolt (1).

    6. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  6. Install the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement.

    7. Object Number: 1866354 Size: SH
  7. Install the fuel return pipe to the fuel return hoses.
  8. Position the fuel return hose clamps (2).
  9. Install the fuel return pipe upper clamp and bolt (1).

    10. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  10. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
  11. Install the water outlet. Refer to Water Outlet Tube Replacement.
  12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  13. Prime the fuel system. Refer to Fuel System Priming.
  14. Start the engine. If the engine stalls, repeat the above step.
  15. Once the engine starts, inspect for fuel leaks.