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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 4.8L, 5.3L, AND 6.0L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL RAIL ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Fuel Injector, Clip & O-Rings
    GM351185Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) to the end of each injector (3).
    3. Fig 2: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
  3. Remove the retaining clip attaching screw (22) and crossover pipe retainer (21) to the right hand fuel rail.
  4. Remove the crossover pipe rail (25) from the right fuel rail (15).
  5. Remove the crossover pipe O-ring (20).
  6. Lubricate a NEW O-ring (20) with clean engine oil.
  7. Install a NEW crossover pipe O-ring (20) on the crossover pipe (25).
  8. Install the crossover pipe (25) into the right fuel rail (15).
    IMPORTANT: When installing the retaining clip attaching screw for the crossover pipe, always start the screw by hand. This will prevent consequent stripping of the threads in the fuel rail.
  9. Loosely install the crossover pipe retainer (21) and retaining clip attaching screw (22) to the right fuel rail.
    10. Fig 3: View Of Fuel Rail
    GM376389Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel rail.
  11. Apply a 5 mm (0.020 in) band of GM P/N 12345382 (Canadian P/N 10953489) threadlock, or equivalent, to the threads of the fuel rail bolts.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  12. Install the fuel rail bolts.

    Tighten: 

    1. Tighten the bolts to 10 N.m (89 lb in).
    2. Tighten the screw to 3.8 N.m (34 lb in).

    13. Fig 4: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel pressure regulator vacuum line.
  14. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
  15. Connect the fuel injector electrical connectors.
    • Install each connector onto the correct injector in order to ensure correct sequential injector firing order.
    • Rotate the injectors as required in order to avoid stretching the wire harness.
    16. Fig 5: Identifying Upper Engine Wire Harness Retainer
    GM310125Courtesy of GENERAL MOTORS CORP.
  16. Position the upper engine wire harness in place.
  17. Connect the EVAP purge solenoid connector.
  18. Install the retainer nut to the upper engine wire harness.

    Tighten:  Tighten the nut to 5.5 N.m (49 lb in).

    19. Fig 6: Locating Accelerator Control Cable and Cruise Control Cable
    GM389853Courtesy of GENERAL MOTORS CORP.
  19. Connect the accelerator control cable and the cruise control cable to the cable bracket, if equipped.
    20. Fig 7: View Of Accelerator/Throttle Cable
    GM389031Courtesy of GENERAL MOTORS CORP.
  20. Connect the accelerator control cable to the throttle body, if equipped.
    21. Fig 8: Removing Cruise Control Cable End From Throttle Linkage
    GM1199275Courtesy of GENERAL MOTORS CORP.
  21. Connect the cruise control cable engine-end fitting to the stud on the throttle lever, if equipped.
  22. Install the air cleaner resonator outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement .
  23. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
  24. Use the following procedure in order to inspect for leaks:
    1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
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.