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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 679 (ENGINE CONTROLS - 8.1L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL 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 2006 GMC Sierra, 2006 GMC Cab & Chassis Sierra, 2006 Chevrolet Silverado, and 2006 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: An eight digit identification number is located on the fuel rail. Refer to this number if servicing, or part replacement is required.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical - 8.1L.
  3. Disconnect the generator electrical connector (2).
    Fig 1: View Of Generator, Injector Harness, Ignition Coil Harness, ETC & Purge Valve Solenoid Electrical Connectors
    GM1235689Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
  5. Disconnect the electronic throttle control (ETC) electrical connector (5).
  6. Remove the engine harness bolt and studs.
  7. Reposition the engine harness to the drivers side of the engine compartment.
  8. Identify the fuel injector connectors to their corresponding injectors in order to ensure correct sequential injector firing order after reassembly.
    Fig 2: Identifying Lock Release
    GM372749Courtesy of GENERAL MOTORS CORP.
  9. Pull the top portion (2) of the connector up. Do not pull the top portion of the connector past the top of the white portion (1).
  10. Push the tab (1) on the lower side of the connector in order to release the connector from the injector.
    Fig 3: Disconnecting Fuel Injector Electrical Connectors
    GM372753Courtesy of GENERAL MOTORS CORP.
  11. Repeat step 12 and step 13 for each injector connector.
    12. NOTE:
    • Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
    • Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
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.