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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 918 (ENGINE CONTROL SYSTEM & FUEL - 4.8L, 5.3L, 6.0L AND 6.2L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL 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 does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Rail Cross Over Pipe & Components
    GM1706110Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the NEW fuel rail crossover pipe O-ring seals with clean engine oil.
  2. Install NEW fuel rail crossover pipe O-ring seals (4) onto the crossover pipe.
  3. Install the fuel rail crossover pipe (1) into the fuel rails.
  4. Install the fuel rail crossover pipe retainers (3).
    5. NOTE: Refer to Fastener Notice .
  5. Install the fuel rail crossover pipe retainer screws (2)

    Tighten:  Tighten the screws to 3.8 N.m (34 lb in).

    6. Fig 2: View Of Fuel Rail & Components
    GM1706106Courtesy of GENERAL MOTORS CORP.
  6. Lubricate the NEW fuel injector O-ring seals with clean engine oil.
  7. Install the NEW fuel injector upper and lower O-ring seals (2 and 4) onto the injectors.
  8. Install the fuel injectors (3) into the fuel rails.
  9. Install the fuel injector retainers (1).
    10. Fig 3: View Of Fuel Rail & Bolts
    GM1697066Courtesy of GENERAL MOTORS CORP.
  10. Ensure the fuel injector lower O-ring seals are adequately lubricated, if not lubricate the fuel injector lower O-ring seals with clean engine oil.
  11. Position the fuel rail onto the intake manifold.
  12. Firmly push down on both the centers of the left and right fuel rails, until the rails are fully seated against the intake manifold.
    13. IMPORTANT: Push down firmly on both sides of the rail until all injectors have been seated into their bores.
  13. Install the fuel rail bolts.

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

    14. Fig 4: View Of EVAP Tube & Purge Solenoid
    GM1697062Courtesy of GENERAL MOTORS CORP.
  14. Install the EVAP tube and purge solenoid.
  15. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer.
  16. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to Quick Connect Fitting Service - Plastic Collar .
    17. Fig 5: View Of EVAP Canister Purge Tube & Quick Connect Fitting
    GM1696917Courtesy of GENERAL MOTORS CORP.
  17. Connect the chassis fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to Quick Connect Fitting Service - Metal Collar .
    18. Fig 6: View Of PCV Hose
    GM1696791Courtesy of GENERAL MOTORS CORP.
  18. Install the PCV hose.
  19. Gather the branches of the engine wiring harness and position over the top of the engine.
    20. Fig 7: View Of Engine Wiring Harness, Clip, Bolt & Connector
    GM1696914Courtesy of GENERAL MOTORS CORP.
  20. Position the engine wiring harness clip to the generator bracket and install the clip bolt (3).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    21. Fig 8: View Of Battery Cable Terminals & Stud
    GM1699543Courtesy of GENERAL MOTORS CORP.
  21. Position the negative battery cable terminal (2) and engine wiring harness ground terminal (3) to the right cylinder head.
  22. Install the negative battery cable stud (1) to the cylinder head.

    Tighten:  Tighten the stud to 25 N.m (18 lb ft).

    23. Fig 9: View Of CPA Retainer, Engine Harness Electrical Connectors & Harness Clips
    GM1696893Courtesy of GENERAL MOTORS CORP.
  23. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector.
  24. Install the CPA retainer (2).
  25. Connect the engine wiring harness electrical connector (3) to the electronic throttle control.
  26. Connect the engine wiring harness electrical connectors (7) to the fuel injectors, perform the following:
    1. Ensure that the CPA retainer is pulled out 1 click.
    2. Connect the electrical connectors to their corresponding injectors.
    3. Push the CPA retainer in 1 click.
    4. Ensure that the connector is secured.
  27. Install the engine wiring harness clip (4) to the generator battery jumper cable.
  28. Install the engine wiring harness clip (6) to the ignition coil bracket stud.
    29. Fig 10: View Of CPA Retainer, Electrical Connectors & Engine Harness Clips
    GM1696892Courtesy of GENERAL MOTORS CORP.
  29. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector.
  30. Install the CPA retainer (2).
  31. Connect the engine wiring harness electrical connectors (3) to the fuel injectors, perform the following:
    1. Ensure that the CPA retainer is pulled out 1 click.
    2. Connect the electrical connectors to their corresponding injectors.
    3. Push the CPA retainer in 1 click.
    4. Ensure that the connector is secured.
    32. Fig 11: View Of Engine Harness Retainer Nut & Electrical Connectors
    GM1696891Courtesy of GENERAL MOTORS CORP.
  32. Connect the engine wiring harness electrical connector (4) to the MAP sensor.
  33. Connect the engine wiring harness electrical connector (3) to the generator.
  34. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid.
  35. Install the engine wiring harness bracket nut (1).

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

  36. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  37. 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 leaks.
  38. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct 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.