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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1703 (ENGINE CONTROLS AND FUEL - 2.4L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027-100)  or Fuel Pressure Relief (Without CH 48027-100) .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
    5. Fig 1: View Of Fuel Feed Pipe Retainer & Fuel Pipe Bracket
    GM1683133Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  6. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
  7. Disconnect the fuel injector wiring harness electrical connector from the engine wiring harness electrical connector.
    8. Fig 2: View Of Fuel Rail
    GM1578472Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel injection fuel rail assembly bolts.
    9. NOTE: Use care when removing the fuel injection fuel rail assembly in order to prevent damage to the fuel injector spray tips.
  9. Pull the fuel injector fuel rail assembly back and upward in order to release the fuel injectors from the cylinder head ports.
  10. Remove the fuel injection fuel rail assembly.
    11. Fig 3: View Of Fuel Injector Tip Insulators
    GM1336272Courtesy of GENERAL MOTORS CORP.
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.