Express, Savana, G1500, G2500, G3500, 1998-2005

Injection Lines

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Removal & Installation



  1. Remove the fuel feed pipe attaching nuts and bolts.
  2.  
  3. Remove the fuel feed pipe.

    Click image to see an enlarged view

    Fig. Remove the fuel feed pipe

  4.  
  5. Disconnect the fuel rail balance pipe from fuel rails.
  6.  
  7. Remove the fuel rail balance pipe bolts.
  8.  
  9. Remove the fuel rail balance pipe.

    Click image to see an enlarged view

    Fig. Remove the fuel rail balance pipe

  10.  
  11. Remove the left fuel return hose.

    Click image to see an enlarged view

    Fig. Fuel return hose-left side shown

  12.  
  13. Remove the right fuel return hose.
  14.  
  15. Disconnect the fuel hoses from the fuel injector pump.
  16.  
  17. Remove the distribution block and fuel line assembly bolts.
  18.  
  19. Remove the distribution block and fuel line assembly.

    Click image to see an enlarged view

    Fig. Remove the distribution block and fuel line assembly

  20.  
  21. Remove the fuel pipe assembly bracket bolts.
  22.  
  23. Remove the fuel pipe assembly bracket.
  24.  
  25. Remove the coolant pipe bolt and nut.
  26.  
  27. Remove the coolant pipe.

    Click image to see an enlarged view

    Fig. Remove the coolant pipe

  28.  
  29. Remove the left fuel rail to pump pipe.
  30.  
  31. Remove the EGR mounting bracket bolts.
  32.  
  33. Remove the EGR mounting brackets.
  34.  
  35. Using compressed air to blow away any debris between the fuel injector line and the fittings. Wipe clean the fittings of debris.
    WARNING
    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.

  36.  
  37. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fitting to contain any debris during removal.
  38.  
  39. Remove the left fuel injector pipes.

    Click image to see an enlarged view

    Fig. Fuel injector pipes-left side shown

  40.  
  41. Remove the right fuel injector pipes.
  42.  
  43. Remove the left fuel rail and bracket bolts.
  44.  
  45. Remove the left fuel rail and bracket.

    Click image to see an enlarged view

    Fig. Fuel rail and bracket-left side shown

  46.  
  47. Remove the right fuel rail bolts.
  48.  
  49. Remove the right fuel rail.
  50.  

To install:

  1. Install the right fuel rail.
  2.  
  3. Install the right fuel rail mounting bolts.
  4.  
  5. Tighten the right fuel rail mounting bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Install the left fuel rail.
  8.  
  9. Install the left fuel rail mounting bolts.
  10.  
  11. Tighten the left fuel rail mounting bolts to 18 ft. lbs. (25 Nm).
    CAUTION
    Improper torque methods of the fuel lines will result in fuel leaks and possible damage to the engine. Failure to follow proper fuel line fitting torque methods could result in serious personal injury.



    Click image to see an enlarged view

    Fig. Fuel rail and bracket-left side shown

  12.  
  13. Install the injection pipes to the right bank.
    1. Tighten the injection pipes to 30 ft. lbs. (41 Nm)
    2.  

  14.  
  15. Install the injection pipes to the left bank.
    1. Tighten the injection pipes to 30 ft. lbs. (41 Nm)

      Click image to see an enlarged view

      Fig. Fuel injector pipes-left side shown

    2.  

  16.  
  17. Install the EGR mounting brackets.
  18.  
  19. Install the EGR mounting bracket bolts.
    1. Tighten the EGR mounting bracket bolts to 15 ft. lbs. (20 Nm).
    2.  

  20.  
  21. Install the left fuel rail to pump pipe.
    1. Tighten the fuel rail to pump pipe nut to 30 ft. lbs. (41 Nm).
    2.  

  22.  
  23. Install the coolant pipe.
  24.  
  25. Install the coolant pipe bolt and nut.
    1. Tighten the coolant pipe bolt and nut to 18 ft. lbs. (25 Nm).
    2.  

  26.  
  27. Install the fuel pipe assembly bracket.
  28.  
  29. Install the fuel pipe assembly bracket bolts.
    1. Tighten the fuel pipe assembly bracket bolts to 18 ft. lbs. (25 Nm).
    2.  

  30.  
  31. Install the distribution block and fuel line assembly.
  32.  
  33. Install the distribution block and fuel line assembly bolts.
    1. Tighten the fuel line assembly bolts to 18 ft. lbs. (25 Nm).
    2.  

  34.  
  35. Connect the fuel hoses to the fuel injector pump.
  36.  
  37. Install the right fuel return hose.
  38.  
  39. Install the left fuel return hose.

    Click image to see an enlarged view

    Fig. Fuel return hose-left side shown

  40.  
  41. Install the fuel rail balance pipe.
  42.  
  43. Install the fuel rail balance pipe bolts.
    1. Tighten the fuel rail balance pipe bolts to 15 ft. lbs. (21 Nm).
    2.  

  44.  
  45. Connect the fuel rail balance pipe to the fuel rails.
    1. Tighten the fuel rail balance pipe nuts to 30 ft. lbs. (41 Nm).
    2.  

  46.  
  47. Install the fuel feed pipe.
  48.  
  49. Install the fuel feed pipe attaching nuts and bolts.
    1. Tighten the fuel feed pipe bolts and nut to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Install the fuel feed pipe

    2.  

  50.  

6.5L Engine

NOTE
When the fuel lines are to be removed, clean all fuel line fittings thoroughly before loosening. Immediately cap the lines, nozzles and pump fittings to maintain cleanliness.

  1. Disconnect both batteries.
  2.  
  3. Disconnect the air cleaner bracket at the valve cover.
  4.  
  5. Remove the crankcase ventilator bracket and move it aside.
  6.  
  7. Disconnect the secondary filter lines.
  8.  
  9. Remove the secondary filter adapter.
  10.  
  11. Loosen the vacuum pump hold-down clamp and rotate the pump in order to gain access to the intake manifold bolt. Remove the intake manifold bolts. The injection line clips are retained by the same bolts.

    Click image to see an enlarged view

    Fig. Injection line routing-6.5L engines

  12.  
  13. Remove the intake manifold. Install a protective cover (GM part no. J-29664-1 or equivalent) so no foreign material falls into the engine.
  14.  
  15. Remove the injection line clips at the loom brackets.
  16.  
  17. Remove the injection lines at the nozzles and cover the nozzles with protective caps.
  18.  
  19. Remove the injection lines at the pump and tag the lines for later installation.
  20.  
  21. Remove the fuel line from the injection pump.
  22.  

To install:

  1. Install the injection lines at the pump and nozzles. Tighten all fittings to 20 ft. lbs. (25 Nm).
  2.  
  3. Install the injection line clips at the loom bracket.
  4.  
  5. Install the intake manifold.
  6.  
  7. Install the alternator bracket and tighten the manifold bolts.
  8.  
  9. Install the fuel lines at the filter. Tighten the bolts to 9 inch lbs. (1 Nm).
  10.  
  11. Install the filter to the manifold and tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Install the air cleaner and the crankcase ventilator bracket.
  14.  
  15. Connect the batteries.
  16.  

 
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