GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series Motorhome (Cutaway) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L (LLY) 🢒 Fuel Injection Fuel Feed Manifold Replacement

Removal Procedure
  1. Remove the air cleaner. Refer to Air Cleaner Replacement .
  2. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .
  3. Remove the charged air pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
  4. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  5. Reposition the fuel hose clamp at the return/junction block.
  6. Remove the hose from the return/junction block.
  7. Disconnect the right fuel return line from the return/junction block line.

    8. Object Number: 1387888 Size: SH
  8. Reposition the return/junction block hose clamps (3).
  9. Remove the return/junction block hoses.
  10. Remove the return/junction block line clamp bolt (2).
  11. Remove the return/junction block bolt (1).
  12. Remove the return junction block.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1387888 Size: SH
  1. Install the return junction block.
  2. Install the return/junction block bolt (1).
  3. Install the return/junction block line clamp bolt (2).

    4. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  4. Install the return/junction block hoses.
  5. Position the return/junction block hose clamps (3).
  6. Connect the right fuel return line to the return/junction block line.
  7. Install the hose to the return/junction block.
  8. Position the fuel hose clamp at the return/junction block.
  9. Install the charged air pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
  10. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
  11. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  12. Install the air cleaner. Refer to Air Cleaner Replacement .
  13. Prime the fuel system. Refer to Fuel System Priming .
  14. Start the engine. If the engine stalls, repeat step 13.
  15. Once the engine starts, inspect for fuel leaks.