GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2002 🢒 GMC K Sierra - 4WD 🢒 Engine 🢒 Engine Controls - 6.6L 🢒 Fuel Injection Fuel Rail Assembly Replacement - Bank 1

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.

  1. Disconnect the negative battery cables from both batteries.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling .

    3. Important: Cover the air intake pipe with tape to keep foreign material out.

  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .

    4. Object Number: 664851 Size: SH
  4. Remove the right side charged air outlet hose and clamps.

    5. Object Number: 687021 Size: SH
  5. Remove the positive crankcase ventilation (PCV) hose and clamp.
  6. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  7. Remove the fuel filter. Refer to Fuel Filter Replacement
  8. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement .

    9. Object Number: 660438 Size: SH
  9. Disconnect the high pressure fuel rail line coming from the junction block (1).

    10. Object Number: 660502 Size: SH
  10. Loosen the high pressure injection lines at the four injectors.
  11. Loosen the high pressure lines injection at the four fittings on the fuel rail.
  12. Mark the high pressure injection lines in order and remove them.

    13. Object Number: 660459 Size: SH
  13. Remove the three bolts holding the fuel rail.

Installation Procedure

    Object Number: 660459 Size: SH
  1. Install the new fuel rail and bolts.

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


    Object Number: 660502 Size: SH
  2. Connect the high pressure lines between the fuel rail and injectors.

    3. Tighten
    Tighten the high pressure lines to 44 N·m (33 lb ft).

  3. Attach the high pressure line to the back of the fuel rail

    4. Tighten
    Tighten the fuel rail bolts to 26 N·m (19 lb ft).


    Object Number: 660438 Size: SH
  4. Connect the high pressure fuel line at the end of the fuel rail (1).
  5. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement .
  6. Install the fuel filter. Refer to Fuel Filter Replacement .
  7. Connect the fuel injection control module. Refer to Fuel Injector Control Module Replacement .

    8. Object Number: 687021 Size: SH
  8. Attach the PCV hose and clamp.

    9. Object Number: 664851 Size: SH
  9. Attach the charged air outlet hose and clamp.
  10. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  11. Install the bolt holding the positive battery cable junction box and bracket.
  12. Replace the upper radiator hose and the two hose clamps.
  13. Fill the cooling system. Refer to Cooling System Draining and Filling .
  14. Connect the negative battery cables to both batteries.
  15. Replace all hold down ties.
  16. Start the engine and check for leaks or noises.
  17. After the engine warms up, refill the coolant reservoir.