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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1239 (ENGINE CONTROLS AND FUEL - 2.2L (L61) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Install only NEW lower O-rings if the fuel rail and injectors were removed and re-installed If the fuel rail was replaced, then install NEW upper and lower O-rings.
    Fig 1: View Of Fuel Rai & Injectors
    GM1683401Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
  2. Install the fuel injector wiring harness clips to the fuel rail.
  3. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    4. Fig 2: View Of Fuel Injector Tip Insulators
    GM1336272Courtesy of GENERAL MOTORS CORP.
  4. Lubricate the NEW fuel injector tip insulators with clean engine oil.
  5. Install the NEW fuel injector tip insulators to the cylinder head.
    6. Fig 3: View Of Fuel Rail
    GM1578472Courtesy of GENERAL MOTORS CORP.
  6. Lubricate the fuel injector O-rings with clean engine oil.
  7. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  8. Carefully push down on the fuel rail in order the insert the injectors into the cylinder head ports.
    9. NOTE: Refer to Fastener Notice .
  9. Install the fuel rail bolts.

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

    10. Fig 4: Identifying Engine Wiring Harness Electrical Connector
    GM1773491Courtesy of GENERAL MOTORS CORP.
  10. Connect the engine wiring harness electrical connector to the fuel injector harness wiring electrical connector (2).
  11. Install the fuel injector wiring harness electrical connector rosebud clip (1) to the intake manifold.
    12. Fig 5: View Of Engine Wiring Harness Clips
    GM1792459Courtesy of GENERAL MOTORS CORP.
  12. Install the engine wiring harness clips (1) to the fuel rail tabs.
    13. Fig 6: View Of ETC
    GM1773494Courtesy of GENERAL MOTORS CORP.
  13. Connect the engine wiring harness electrical connector to the ETC.
    14. Fig 7: Identifying Engine Compartment Fuel Feed Line
    GM1773498Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel feed line quick connect fitting (4) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  15. Install the air cleaner outlet resonator. 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.