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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 2 (ENGINE CONTROL SYSTEM - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL HOSE/PIPES REPLACEMENT - ENGINE COMPARTMENTINSTALLATION 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: Expanded View Of Fuel Pipe O-Ring Seals
    GM12858Courtesy of GENERAL MOTORS CORP.
  1. Assemble the new O-rings into the inlet and outlet of the fuel injector assembly.
    2. CAUTION: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
  2. Apply a few drops of clean engine oil to the male tube ends.
  3. Install the fuel feed and return pipes to the injector assembly.
    4. Fig 2: Locating Injector Fuel Inlet/Outlet Pipe Retainer Nuts
    GM12855Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel pipe retainer and the attaching nuts.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the retaining bolt to the rear fuel pipe bracket.

    Tighten: 

    1. Tighten the bracket bolt to 6 N.m (53 lb in).
    2. Tighten the retainer nuts to 3 N.m (27 lb in).

    6. Fig 3: Fuel, EVAP, Chassis Fuel (Feed & Return Pipes)
    GM588985Courtesy of GENERAL MOTORS CORP.
  6. Install the new O-ring seals on the engine fuel feed and the return pipes.
  7. Install the chassis fuel feed and return pipes (3) to the engine compartment fuel feed and return pipes (4).

    Tighten:  Tighten the fuel pipe nuts to 27 N.m (20 lb ft).

  8. Install the retainer nut to the fuel and EVAP pipe.

    Tighten:  Tighten the retainer nut to 28 N.m (21 lb ft).

  9. Tighten the fuel filler cap.
  10. Connect the negative battery cable.
  11. Inspect for leaks:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
  12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement .
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.