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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 483 (ENGINE CONTROLS - 6.0L - ALTERNATIVE FUELS (INTRODUCTION))REPAIR INSTRUCTIONSFUEL RAIL ASSEMBLY REPLACEMENT (KL8)INSTALLATION 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 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Fuel Injector Connectors
    GM757006Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel rails (3, 4) into the intake manifold.
  2. Apply a 5 mm (0.020 in) band of GM P/N 1234382 threadlock, or equivalent, to the threads of the fuel rail attaching bolts.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel rail attaching bolts (1).

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

  4. Connect the fuel injector electrical connectors (6) to the corresponding engine cylinder injector.
  5. Connect the fuel rail pressure and temperature sensor electrical connectors (2, 7).
    6. Fig 2: Identifying IPR Fuel Outlet Lines Components
    GM757010Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel lines (5, 8) into the fuel rails (1, 10) using new O-rings. Lubricate the O-rings with petroleum jelly.
  7. Install the fuel line to rail retainers (7) and clamps (9).

    Tighten:  Tighten the clamps to 2 N.m (18 lb in).

    8. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  8. Install the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical in the C/K Pickup service manual.
  9. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings using the J 45878  or an equivalent liquid leak detector. See Special Tools and Equipment .
    10. Fig 3: View Of Top Engine Cover
    GM665886Courtesy of GENERAL MOTORS CORP.
  10. Install the engine sight shield (2). Refer to Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines) Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88) in Engine Mechanical in the C/K Pickup service manual.
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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.