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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 939 (ENGINE CONTROLS - 6.6L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENT - BANK 2INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation Procedure
WARNING: This page is about a different car, the 2001 GMC Sierra, 2001 GMC Cab & Chassis Sierra, 2001 Chevrolet Silverado, and 2001 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Rail And Bolts
    GM660456Courtesy of GENERAL MOTORS COMPANY
  1. Install the new fuel rail and bolts.
    2. Fig 2: Left Fuel Injector Feed Pipes
    GM660451Courtesy of GENERAL MOTORS COMPANY
  2. Refer to Fastener Notice .

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

    Tighten 

    Tighten the high pressure lines to 44 N.m (32 lb ft).

    3. Fig 3: Fuel Junction Block
    GM660449Courtesy of GENERAL MOTORS COMPANY
  3. Install the junction block assembly.
    4. Fig 4: View Of Left Fuel Rail High Pressure Line & Left Cylinder Head Return Line Eye Bolt & Gasket
    GM660446Courtesy of GENERAL MOTORS COMPANY
  4. Connect the high pressure line (1) to the back end of the fuel rail.

    Tighten 

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

    5. Fig 5: View Of Fuel Return Hose & Fuel Injection Pump High Pressure Line From Fuel Injection Pump
    GM660448Courtesy of GENERAL MOTORS COMPANY
  5. Install the line from the junction block to the injection pump.
    6. Fig 6: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS COMPANY
  6. Install the bolts holding the air conditioning compressor.
  7. Install drive belt. Refer to Drive Belt Replacement .
  8. Install the water outlet pipe to thermostat housing.
    9. Fig 7: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS COMPANY
  9. Attach the PCV hose and clamp.
  10. Install the L-bracket holding the fuel lines.
  11. Connect the fuel lines.
  12. Install the glow plug bracket.
  13. Install the glow plug relay. Refer to Glow Plug Relay Replacement (California) , Glow Plug Relay Replacement (Federal) .
    14. Fig 8: Glow Plug Relay Electrical Connectors
    GM786978Courtesy of GENERAL MOTORS COMPANY
  14. Connect the connectors to the glow plug relays (1, 2, 3).
    15. Fig 9: Turbocharged Air Hose View
    GM664853Courtesy of GENERAL MOTORS COMPANY
  15. Attach the turbo hose and clamp at the turbo to the intercooler.
  16. Install the bolt holding the positive battery cable junction box and bracket.
  17. Replace the upper radiator hose and two hose clamps.
  18. Replace the coolant. Refer to Cooling System Draining and Filling .
  19. Connect the negative battery cables to both batteries.
  20. Replace all hold down ties.
  21. Start the engine and check for leaks or noises.
  22. After the engine warms up, refill the coolant reservoir to the proper level.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.