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Tahoe / Yukon Service Manual

High Pressure Diesel Fuel Feed to Rail Pipe Replacement

Single Use Fasteners and Components Exhaust Gas Recirculation Cooler Inlet Pipe Gasket Exhaust Gas Recirculation Pipe Seal High Pressure Diesel Fuel Feed to Rail Pipe

  1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
  2. Plenum Front Panel Outer Reinforcement » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 1
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 1
  1. Oil Filler Cap » Remove
  2. Intake Manifold Cover Bolt (1) » Remove
  3. Intake Manifold Cover (2) » Remove
  4. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 2
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 2
  1. Air Cleaner Outlet Front Duct Clamp (1) » Loosen [2x]
  2. Air Cleaner Outlet Front Duct (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 3
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 3
  1. Air Cleaner Outlet Duct Clamp (1) » Loosen
  2. Air Cleaner Outlet Duct (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 4
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 4
  1. Remove the 3 rear engine wiring harness channel nuts (1).
  2. Position the rear engine wiring harness channel (2) out of the way.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 5
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 5
  1. Engine Coolant Outlet Pipe Bracket Bolt (1) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 6
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 6
  1. Remove the 2 exhaust gas recirculation cooler bolts (1).
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 7
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 7
  1. Remove the turbocharger coolant feed pipe bolt (3) and position the turbocharger coolant feed pipe (2) out of the way.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 8
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 8
  1. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
  2. Remove the exhaust gas recirculation pipe bolt (2).
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 9
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 9
  1. Remove the 2 exhaust gas recirculation pipe bolts (1).
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 10
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 10
  1. Exhaust Gas Recirculation Pipe (1) » Remove
  2. Exhaust Gas Recirculation Pipe Seal (2) » Remove and DISCARD
  3. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) » Remove and DISCARD
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 11
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 11
  1. Electrical Connector (1) @ Nitrogen Oxides Sensor » Disconnect
  2. Wiring Harness Retainer (2) @ Charge Air Cooler » Remove [3x]
  3. Electrical Connector (3) @ Charge Air Cooler » Disconnect [2x]
  4. Engine Wiring Harness (4) » Position aside
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 12
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 12
  1. Wiring Harness Retainer (4) @ Charge Air Cooler » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 13
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 13
  1. Charge Air Cooler Outlet Air Hose Clamp (1) » Loosen until disengaged [2x]
  2. Charge Air Cooler Outlet Air Hose (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 14
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 14
  1. Charge Air Cooler Inlet Air Hose Clamp (1) » Loosen until disengaged [2x]
  2. Charge Air Cooler Inlet Air Hose (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 15
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 15
  1. Charge Air Cooler Bolt (1) » Remove [4x]
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 16
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 16
  1. Reposition charge air cooler (1) with coolant hoses attached.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 17
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 17
  1. Upper Intake Manifold Brace Nut (1) » Remove [3x]
  2. Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 18
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 18
  1. Turbocharger Heat Shield Bolt (1) » Remove [2x]
  2. Turbocharger Heat Shield Nut (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 19
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 19
  1. Reposition the turbocharger heat shield (1) with the exhaust gas recirculation temperature sensor attached.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 20
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 20
  1. Release the retaining spring (1).
  2. Intake Manifold Resonator (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 21
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 21
  1. Turbocharger Bracket Bolt (1) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 22
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 22
  1. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
  2. Engine Wiring Harness Bracket (3) » Reposition
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 23
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 23
  1. Oil Filler Tube Support Stud (1) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 24
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 24
  1. Engine Coolant Air Bleed Hose Clip (1) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 25
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 25
  1. Charge Air Cooler Bolt (1) » Remove [5x]
  2. Charge Air Cooler Bracket (2) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 26
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 26
  1. Reposition harness and hoses, and connect electrical connectors as needed.
  2. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Remove
  3. Exhaust Gas Recirculation Pipe Bracket (5) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 27
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 27

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 50. Camshaft Housing Cover Insulator (1) » Remove 51. Front Wheelhouse Liner - Left Side » Remove — Front Wheelhouse Liner Replacement

High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 28
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 28
  1. Fuel Feed Pipe Clip Bolt (1) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 29
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 29
  1. Fuel Pump Fuel Feed Hose (1) » Reposition
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 30
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 30
  1. Diesel Fuel Separator Bracket Bolt (1) » Remove
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 31
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 31
  1. Diesel Fuel Separator (1) » Reposition
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 32
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 32
  1. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 33
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 33
  1. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 34
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 34
  1. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
  2. Unclip the fuel injector fuel return pipe retainer (2).
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 35
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 35
  1. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 36
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 36
  1. High Pressure Diesel Fuel Feed to Rail Pipe (2) » Remove and DISCARD Cleaning and Inspection Procedure - Required
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 37
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 37
  1. Inspect the charge air cooler inlet air hose (2): 1.1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 1.2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found. 1.3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 38
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 38

  1. Inspect the charge air cooler outlet air hose (2): 2.1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces. 2.2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found. 2.3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing. Installation Procedure

  2. High Pressure Diesel Fuel Feed to Rail Pipe (2) » Install NEW

  3. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.

  1. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications

  2. Attach the fuel injector fuel return pipe retainer (2).

  3. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications

  4. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.

  1. Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications

  2. Diesel Fuel Separator (1) » Install

  3. Diesel Fuel Separator Bracket Bolt (1) » Install and tighten — Fastener Specifications

  4. Fuel Pump Fuel Feed Hose (1) » Install

  5. Fuel Feed Pipe Clip Bolt (1) » Install and tighten — Fastener Specifications

  6. Front Wheelhouse Liner - Left Side (3) » Install — Front Wheelhouse Liner Replacement

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 13. Camshaft Housing Cover Insulator (1) » Install

  1. Exhaust Gas Recirculation Pipe Bracket (5) » Install

  2. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

  3. Reposition harness and hoses, and connect electrical connectors as needed.

  4. Charge Air Cooler Bracket (2) » Install

  5. Charge Air Cooler Bolt (1) » Install [5x] — Fastener Specifications

  6. Engine Coolant Air Bleed Hose Clip (1) » Install

  7. Oil Filler Tube Support Stud (1) » Install — Fastener Specifications

  8. Engine Wiring Harness Bracket (3) » Install

  9. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

  10. Turbocharger Bracket Bolt (1) » Install and tighten — Fastener Specifications

  11. Intake Manifold Resonator (2) » Install

  12. Engage the retaining spring (1).

  13. Turbocharger Heat Shield (1) » Install

  14. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

  15. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

  16. Install the upper intake manifold bracket (2) with nitrogen oxides sensor attached.

  17. Upper Intake Manifold Brace Nut (1) » Install and tighten [3x] — Fastener Specifications

  18. Charge Air Cooler (1) » Install

  19. Charge Air Cooler Bolt (1) » Install [4x] — Fastener Specifications

  20. Charge Air Cooler Inlet Air Hose (2) » Install

  21. Charge Air Cooler Inlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

  22. Charge Air Cooler Outlet Air Hose (2) » Install

  23. Charge Air Cooler Outlet Air Hose Clamp (1) » Tighten [2x] — Fastener Specifications

  24. Wiring Harness Retainer (4) @ Charge Air Cooler » Install

  25. Engine Wiring Harness (4) » Reposition

  26. Wiring Harness Retainer (2) @ Charge Air Cooler » Install [3x]

  27. Electrical Connector (3) @ Charge Air Cooler » Connect [2x]

  28. Electrical Connector (1) @ Nitrogen Oxides Sensor » Connect

  29. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) » Install NEW

  30. Exhaust Gas Recirculation Pipe Seal (2) » Install NEW

  31. Exhaust Gas Recirculation Pipe (1) » Install

High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 39
High Pressure Diesel Fuel Feed to Rail Pipe Replacement — figure 39

  1. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

  2. Exhaust Gas Recirculation Outlet Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications.

  3. Exhaust Gas Recirculation Outlet Pipe Bolt (2) » Install and tighten — Fastener Specifications

  4. Install the turbocharger coolant return hose clip (1).

  5. Turbocharger Coolant Feed and Return Pipe Bolt (3) » Install and tighten — Fastener Specifications

  1. Exhaust Gas Recirculation Cooler Bolt (1) » Install and tighten [2x] — Fastener Specifications.

  2. Engine Coolant Outlet Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

  3. Install the rear engine wiring harness channel (2).

  4. Install the 3 rear engine wiring harness channel nuts (1) and tighten. Fastener Specifications

  5. Air Cleaner Outlet Duct (2) » Install

  6. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

  7. Air Cleaner Outlet Front Duct (2) » Install

  8. Air Cleaner Outlet Front Duct Clamp (1) » Tighten [2x] — Fastener Specifications

  9. Oil Filler Cap » Remove

  10. Intake Manifold Cover (2) » Install

  11. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

  12. Oil Filler Cap » Install

  13. Plenum Front Panel Outer Reinforcement » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

  14. Prime the fuel system and inspect for leaks. Fuel System Priming

  15. Check for exhaust leak.