GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Filter Assembly Replacement

Removal Procedure

    Object Number: 1865288 Size: SH
  1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement.
  2. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining.
  3. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
  4. Rotate the electrical connector lever locks (1) rearward.
  5. Disconnect the vehicle's engine wiring harness main electrical connectors (2) from the engine wiring harness main electrical connectors.

    6. Object Number: 1865172 Size: SH
  6. Disconnect the water-in-fuel sensor electrical connector (1) from the engine wiring harness electrical connector.

    7. Object Number: 1865289 Size: SH
  7. Remove the engine wiring harness main electrical connector bracket bolts and reposition the bracket with the main electrical connectors still attached.

    8. Object Number: 1865290 Size: SH
  8. Remove the fuel filter inlet and outlet pipe banjo bolts (2) and washers (1).
  9. Reposition the inlet and outlet pipes/hoses from the fuel filter/heater element housing.

    10. Object Number: 1865291 Size: SH
  10. Remove the fuel filter bracket bolts (2) and nut (1).

    11. Object Number: 1865292 Size: SH
  11. Remove the fuel filter and bracket assembly.

    12. Object Number: 1865295 Size: SH
  12. Remove the fuel filter bracket bolts (1) and bracket (2) from the fuel filter/heater element housing (3).
  13. Remove the fuel filter (4) from the fuel filter/heater element housing (3).
  14. Inspect the fuel filter, replace if necessary.

Installation Procedure

    Object Number: 1865295 Size: SH
  1. Install the fuel filter (4) to the fuel filter/heater element housing (3).

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the fuel filter bracket (2) and bolts (1) to the fuel filter/heater element housing (3).

    3. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).


    Object Number: 1865292 Size: SH
  3. Position the fuel filter and bracket assembly to engine.

    4. Object Number: 1865291 Size: SH
  4. Install the fuel filter bracket bolts (2) and nut (1).

    5. Tighten
    Tighten the bolts/nuts to 20 N·m (15 lb ft).


    Object Number: 1865290 Size: SH

    Note: Lubricate the NEW washers with diesel fuel before installing.

  5. Install NEW washers (1) onto the fuel inlet and outlet pipe fittings.
  6. Position the inlet and outlet pipes/hoses to the fuel filter/heater element housing.
  7. Install the fuel filter inlet and outlet pipe banjo bolts (2).

    8. Tighten
    Tighten the bolts to 26 N·m (19 lb ft).


    Object Number: 1865289 Size: SH
  8. Position the bracket with the main electrical connectors still attached and install the engine wiring harness main electrical connector bracket bolts.

    9. Tighten
    Tighten the bolts to 21 N·m (15 lb ft).


    Object Number: 1865172 Size: SH
  9. Connect the water-in-fuel sensor electrical connector (1) to the engine wiring harness electrical connector.

    10. Object Number: 1865288 Size: SH
  10. Connect the vehicle's engine wiring harness main electrical connectors (2) to the engine wiring harness main electrical connectors.
  11. Rotate the electrical connector lever locks (1) forward.
  12. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
  13. Install the air cleaner. Refer to Air Cleaner Assembly Replacement.
  14. Prime the fuel system. Refer to Fuel System Priming.
  15. Start the engine. If the engine stalls, repeat step 14.
  16. Once the engine starts, inspect for fuel leaks.