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HOMESERVICE MANUALSCHEVROLET2006SUBURBAN C2500, 6.0 UREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 377 (ENGINE CONTROLS - 4.8L, 5.3L, & 6.0L (INTRODUCTION))REPAIR INSTRUCTIONSFUEL RAIL ASSEMBLY REPLACEMENT (5.3L (L59) ENGINE)INSTALLATION PROCEDURE
2006 Chevrolet Suburban C2500, 6.0 U

Installation Procedure

2006 Chevrolet Suburban C2500, 6.0 USECTION Installation 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. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto each injector, if necessary.
    3. Fig 1: View Of Fuel Injector, Clip & O-Rings
    GM351185Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel rail.
  4. Apply a 5 mm (0.020 in) band of threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts.
    5. NOTE: Refer to the Fastener Notice in Cautions and Notices.
  5. Install the fuel rail bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    6. Fig 2: View Of Fuel Injector Rail
    GM260176Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel pressure regulator vacuum line.
  7. Connect the fuel feed and return pipes (1, 2) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    8. Fig 3: View Of EVAP/Fuel Hose/Pipes
    GM856643Courtesy of GENERAL MOTORS CORP.
  8. Install the PCV hose.
    9. Fig 4: View Of PCV Hose
    GM1201537Courtesy of GENERAL MOTORS CORP.
  9. Perform the following steps in order to connect the fuel injector electrical connectors.
    1. Install the connectors to their corresponding injectors to ensure correct reassembly.
    2. Connect the fuel injector electrical connector.
    3. Push the CPA retainer (2) in the connector in 1 click.
    4. Repeat the steps for each injector electrical connector.
    10. Fig 5: CPA Retainer & Tab
    GM820977Courtesy of GENERAL MOTORS CORP.
  10. Position the engine wire harness.
  11. Connect the following electrical connectors to both sides of the engine:
    • Main coil (2)
    • Fuel injectors
  12. Install the harness clips to the fuel rail (1).
    13. Fig 6: View Of Main Ignition Coil Wire Harness Connector & Clips
    GM757686Courtesy of GENERAL MOTORS CORP.
  13. Install the CPA retainers.
  14. Connect the following electrical connectors:
    • MAP sensor (1)
    • Knock sensor (2)
    15. Fig 7: View Of MAP Sensor & Knock Sensor Electrical Connectors
    GM679510Courtesy of GENERAL MOTORS CORP.
  15. Install the knock sensor harness connector to the intake manifold.
  16. Connect the EVAP purge solenoid electrical connector (1).
  17. Connect the generator electrical connector (3).
  18. Install the wire harness bracket nut (2).

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

    19. Fig 8: View Of EVAP Canister Purge Solenoid & Generator Electrical Connectors & Bracket Nut
    GM1235683Courtesy of GENERAL MOTORS CORP.
  19. Tighten the fuel fill cap.
  20. Connect 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.
  21. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, 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.