GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Express 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Return Pipe Replacement

Special Tools

    • J 43178 Fuel Line Disconnect Tool
    • J 44581 Fuel Line Disconnect Tool

Removal Procedure
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Remove the charge air cooler inlet pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement .
  3. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement .
  4. Using the J 43178 and J 44581 , disconnect the fuel feed and return pipes.

    5. Object Number: 1734168 Size: SH
  5. Remove the fuel line bracket bolt.

    6. Object Number: 1728393 Size: SH
  6. Remove the fuel line bracket bolt (1).

    7. Object Number: 1728447 Size: SH
  7. Remove the fuel line bracket bolt.

    8. Object Number: 1732300 Size: SH
  8. Disconnect the fuel rail temperature (FRT) sensor electrical connector.

    9. Object Number: 1734290 Size: SH
  9. Compress the clamp and disconnect the hose from the fuel return line.
  10. Disconnect the left fuel return hose from the fuel return pipe.
  11. Remove the exhaust gas recirculation (EGR) cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .

    12. Object Number: 1734312 Size: SH
  12. Disconnect the right fuel return hose from the fuel return pipe.
  13. Remove the pipe bracket bolt.

    14. Object Number: 1731671 Size: SH
  14. Remove the fuel return pipe from the vehicle.

Installation Procedure

    Object Number: 1731671 Size: SH
  1. Install the fuel return pipe to the vehicle.

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

  2. Install the fuel return pipe bracket.

    3. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1734312 Size: SH
  3. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement .
  4. Connect the right fuel return hose to the fuel return pipe.

    5. Object Number: 1734290 Size: SH
  5. Connect the left fuel return hose to the fuel return pipe.
  6. Compress the clamp and connect the hose to the fuel return line.

    7. Object Number: 1732300 Size: SH
  7. Connect the FRT sensor electrical connector.

    8. Object Number: 1728447 Size: SH
  8. Install the fuel line bracket bolt.

    9. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1728393 Size: SH
  9. Install the fuel line bracket bolt (1).

    10. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 1734168 Size: SH
  10. Install the fuel line bracket bolt.

    11. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  11. Connect the fuel feed and return pipes.
  12. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement .
  13. Install the charge air cooler inlet pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement .
  14. Prime the fuel system. Refer to Fuel System Priming .
  15. Start the engine.

    16. If the engine does not start, repeat the above step.

  16. Inspect the fuel system for fuel leaks.
  17. Install the engine cover. Refer to Engine Cover Replacement .