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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 380 (ENGINE CONTROLS - 6.6L (LB7) (INTRODUCTION))REPAIR INSTRUCTIONSFUEL RAIL ASSEMBLY REPLACEMENT - BANK 1REMOVAL 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 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  3. Reposition the inlet hose clamps.
  4. Remove the inlet hose from the radiator.
  5. Remove the inlet hose from the water outlet tube.
    6. Fig 1: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  6. Remove the bolt attaching the positive battery cable junction box and bracket and move it out of the way.
  7. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
    IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
    8. Fig 2: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  8. Remove the charged air cooler inlet duct from the turbocharger.
  9. Disconnect the glow plug relay electrical connectors (1, 2, 3).
    10. Fig 3: Glow Plug Relay Electrical Connectors
    GM786978Courtesy of GENERAL MOTORS CORP.
  10. Remove the glow plug bracket.
  11. Disconnect the engine wiring harness connectors.

    Lift up on the latch in order to disconnect the connectors.

    12. Fig 4: View Of Main Engine Harness Electrical Connectors
    GM674653Courtesy of GENERAL MOTORS CORP.
  12. Remove the engine connector bracket and set aside.
  13. Disconnect the fuel in-line and return lines.
  14. Remove the L-bracket holding the fuel lines.
  15. Reposition the positive crankcase ventilation (PCV) hose clamp.
  16. Remove the PCV hose and move it out of the way.
    17. Fig 5: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  17. Remove the water pipe outlet from the thermostat housing.
  18. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  19. Remove the air conditioning (A/C) compressor bolts and position aside.
    20. Fig 6: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  20. Remove the line from the junction block to the injection pump.
    21. Fig 7: View Of Fuel Return Hose & Fuel Injection Pump High Pressure Line From Fuel Injection Pump
    GM660448Courtesy of GENERAL MOTORS CORP.
  21. Loosen the fuel return rear pipe (1) at the back end of the fuel rail and remove.
    22. Fig 8: View Of Left Fuel Rail High Pressure Line & Left Cylinder Head Return Line Eye Bolt & Gasket
    GM660446Courtesy of GENERAL MOTORS CORP.
  22. Remove the fuel junction block.
    23. Fig 9: Fuel Junction Block
    GM660449Courtesy of GENERAL MOTORS CORP.
  23. Remove the fuel injector feed pipe retainer bolts and retainers.
  24. Remove the fuel injector pipes.
    25. Fig 10: Left Fuel Injector Feed Pipes
    GM660451Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

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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.