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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1032 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 2 Of 4)) >> Repair Instructions (Off-Vehicle - Part 2) >> Fuel Pipes and Fuel Rail Removal

Fuel Pipes and Fuel Rail Removal

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the fuel return hose and clamp from the fuel injection pump.
  2. Remove the fuel injection pump high pressure line from the fuel injection pump.
    3. Fig 1: View Of Fuel Return Hose & Fuel Injection Pump High Pressure Line From Fuel Injection Pump
    GM660448Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel inlet hose from the fuel injection pump.
  4. Remove the fuel inlet distribution block bolt and nut.
  5. Remove the fuel inlet distribution block from the fuel return distribution block.
    6. Fig 2: View of Fuel Inlet Distribution Block, Bolt & Nut
    GM798887Courtesy of GENERAL MOTORS CORP.
  6. Remove the fuel inlet to fuel return line clamp bolt.
  7. Remove the fuel inlet to fuel return line clamp.
    8. Fig 3: View Of Fuel Inlet To Fuel Return Line Clamp & Bolt
    GM755230Courtesy of GENERAL MOTORS CORP.
  8. Remove the function block nuts.
    9. Fig 4: View Of Function Block Nuts
    GM798888Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel inlet pipe assembly.
  10. Remove the left fuel rail high pressure line (1).
  11. Remove the left cylinder head return line eye bolt and gasket (2).
    12. Fig 5: View Of Left Fuel Rail High Pressure Line & Left Cylinder Head Return Line Eye Bolt & Gasket
    GM660446Courtesy of GENERAL MOTORS CORP.
  12. Remove the right fuel rail high pressure line (1).
  13. Remove the right cylinder head return line eye bolt and gasket (2).
    14. Fig 6: View Of Right Fuel Rail High Pressure Line & Right Cylinder Head Return Line Eye Bolt & Gasket
    GM798890Courtesy of GENERAL MOTORS CORP.
  14. Remove the fuel return line clamp bolt and clamp.
  15. Remove the fuel pressure limiting valve bracket nut.
    16. Fig 7: View Of Fuel Return Line Clamp & Bolt & Pressure Limiting Valve Bracket Nut
    GM755240Courtesy of GENERAL MOTORS CORP.
  16. Remove the fuel pipes and function block assembly.
    17. Fig 8: View Of Fuel Pipes & Function Block Assembly
    GM798892Courtesy of GENERAL MOTORS CORP.
  17. Use compressed air to blow away any debris between the fuel injector line and the fittings (1, 2). Wipe clean the fittings of debris.
    18. Fig 9: View Of Fuel Injector Line Fittings
    GM1336209Courtesy of GENERAL MOTORS CORP.
    NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.
  18. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fitting (1, 2) to contain any debris during removal.
  19. Remove the anti-rotation locks from the left bank injection pipes.
    20. Fig 10: View Of Left Bank Injection Pipes
    GM798893Courtesy of GENERAL MOTORS CORP.
  20. Remove the injection pipes from the left bank.
  21. Remove the anti-rotation locks from the right bank injection pipes.
    22. Fig 11: View Of Right Bank Injection Pipes
    GM798894Courtesy of GENERAL MOTORS CORP.
  22. Remove the injection pipes from the right bank.
  23. Remove the left fuel rail mounting bolts.
  24. Remove the left fuel rail.
    25. Fig 12: View Of Left Fuel Rail & Mounting Bolts
    GM798919Courtesy of GENERAL MOTORS CORP.
    Fig 13: View Of Right Fuel Rail & Mounting Bolts
    GM798895Courtesy of GENERAL MOTORS CORP.
  25. Remove the right fuel rail mounting bolts.
  26. Remove the right fuel rail.
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