Skip to content
Tahoe / Yukon Service Manual

Fuel Injector Fuel Return Hose Bracket 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 [2x]

  1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
Fuel Injector Fuel Return Hose Bracket Replacement — figure 1
Fuel Injector Fuel Return Hose Bracket Replacement — figure 1
  1. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
Fuel Injector Fuel Return Hose Bracket Replacement — figure 2
Fuel Injector Fuel Return Hose Bracket Replacement — figure 2
  1. Intake Manifold Cover Bolt (1) » Remove
  2. Oil Filler Cap » Remove
  3. Intake Manifold Cover (2) » Remove
  4. Oil Filler Cap » Install
Fuel Injector Fuel Return Hose Bracket Replacement — figure 3
Fuel Injector Fuel Return Hose Bracket Replacement — figure 3
  1. Air Cleaner Outlet Front Duct Clamp (1) » Loosen [2x]
  2. Air Cleaner Outlet Front Duct (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 4
Fuel Injector Fuel Return Hose Bracket Replacement — figure 4
  1. Air Cleaner Outlet Duct Clamp (1) » Loosen
  2. Air Cleaner Outlet Duct (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 5
Fuel Injector Fuel Return Hose Bracket Replacement — figure 5
  1. Remove the 3 engine wiring harness bracket nuts (1).
  2. Position the rear engine wiring harness channel (2) out of the way.
Fuel Injector Fuel Return Hose Bracket Replacement — figure 6
Fuel Injector Fuel Return Hose Bracket Replacement — figure 6
  1. Engine Coolant Outlet Pipe Bracket Bolt (1) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 7
Fuel Injector Fuel Return Hose Bracket Replacement — figure 7
  1. Engine Coolant Air Bleed Hose (2) » Reposition
Fuel Injector Fuel Return Hose Bracket Replacement — figure 8
Fuel Injector Fuel Return Hose Bracket Replacement — figure 8
  1. Remove the 2 exhaust gas recirculation cooler bolts (1).
Fuel Injector Fuel Return Hose Bracket Replacement — figure 9
Fuel Injector Fuel Return Hose Bracket Replacement — figure 9
  1. Remove the turbocharger coolant feed pipe bolt (3) and position the turbocharger coolant feed pipe (2) out of the way.
Fuel Injector Fuel Return Hose Bracket Replacement — figure 10
Fuel Injector Fuel Return Hose Bracket Replacement — figure 10
  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).
Fuel Injector Fuel Return Hose Bracket Replacement — figure 11
Fuel Injector Fuel Return Hose Bracket Replacement — figure 11
  1. Remove the 2 exhaust gas recirculation pipe bolts (1).
Fuel Injector Fuel Return Hose Bracket Replacement — figure 12
Fuel Injector Fuel Return Hose Bracket Replacement — figure 12
  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
Fuel Injector Fuel Return Hose Bracket Replacement — figure 13
Fuel Injector Fuel Return Hose Bracket Replacement — figure 13
  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
Fuel Injector Fuel Return Hose Bracket Replacement — figure 14
Fuel Injector Fuel Return Hose Bracket Replacement — figure 14
  1. Wiring Harness Retainer (4) @ Charge Air Cooler » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 15
Fuel Injector Fuel Return Hose Bracket Replacement — figure 15
  1. Charge Air Cooler Outlet Air Hose Clamp (1) » Loosen until disengaged [2x]
  2. Charge Air Cooler Outlet Air Hose (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 16
Fuel Injector Fuel Return Hose Bracket Replacement — figure 16
  1. Charge Air Cooler Inlet Air Hose Clamp (1) » Loosen until disengaged [2x]
  2. Charge Air Cooler Inlet Air Hose (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 17
Fuel Injector Fuel Return Hose Bracket Replacement — figure 17
  1. Charge Air Cooler Bolt (1) » Remove [4x]
Fuel Injector Fuel Return Hose Bracket Replacement — figure 18
Fuel Injector Fuel Return Hose Bracket Replacement — figure 18
  1. Charge Air Cooler (1) » Reposition
Fuel Injector Fuel Return Hose Bracket Replacement — figure 19
Fuel Injector Fuel Return Hose Bracket Replacement — figure 19
  1. Upper Intake Manifold Brace Nut (1) » Remove [3x]
  2. Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.
Fuel Injector Fuel Return Hose Bracket Replacement — figure 20
Fuel Injector Fuel Return Hose Bracket Replacement — figure 20
  1. Turbocharger Heat Shield Bolt (1) » Remove [2x]
  2. Turbocharger Heat Shield Nut (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 21
Fuel Injector Fuel Return Hose Bracket Replacement — figure 21
  1. Turbocharger Heat Shield (1) » Reposition
Fuel Injector Fuel Return Hose Bracket Replacement — figure 22
Fuel Injector Fuel Return Hose Bracket Replacement — figure 22
  1. Release the retaining spring (1).
  2. Intake Manifold Resonator (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 23
Fuel Injector Fuel Return Hose Bracket Replacement — figure 23
  1. Turbocharger Bracket Bolt (1) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 24
Fuel Injector Fuel Return Hose Bracket Replacement — figure 24
  1. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
  2. Engine Wiring Harness Bracket (3) » Reposition
Fuel Injector Fuel Return Hose Bracket Replacement — figure 25
Fuel Injector Fuel Return Hose Bracket Replacement — figure 25
  1. Oil Filler Tube Support Stud (1) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 26
Fuel Injector Fuel Return Hose Bracket Replacement — figure 26
  1. Engine Coolant Air Bleed Hose Clip (1) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 27
Fuel Injector Fuel Return Hose Bracket Replacement — figure 27
  1. Charge Air Cooler Bolt (1) » Remove [5x]
  2. Charge Air Cooler Bracket (2) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 28
Fuel Injector Fuel Return Hose Bracket Replacement — figure 28
  1. Disconnect electrical connectors, then reposition harness and hoses as needed.
  2. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Remove
  3. Exhaust Gas Recirculation Pipe Bracket (5) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 29
Fuel Injector Fuel Return Hose Bracket Replacement — figure 29

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. 51. Camshaft Housing Cover Insulator (1) » Remove 52. Front Wheelhouse Liner - Left Side » Remove — Front Wheelhouse Liner Replacement

Fuel Injector Fuel Return Hose Bracket Replacement — figure 30
Fuel Injector Fuel Return Hose Bracket Replacement — figure 30
  1. Fuel Feed Pipe Clip Bolt (1) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 31
Fuel Injector Fuel Return Hose Bracket Replacement — figure 31
  1. Fuel Pump Fuel Feed Hose (1) » Reposition
Fuel Injector Fuel Return Hose Bracket Replacement — figure 32
Fuel Injector Fuel Return Hose Bracket Replacement — figure 32
  1. Diesel Fuel Separator Bracket Bolt (1) » Remove
Fuel Injector Fuel Return Hose Bracket Replacement — figure 33
Fuel Injector Fuel Return Hose Bracket Replacement — figure 33
  1. Diesel Fuel Separator (1) » Reposition
Fuel Injector Fuel Return Hose Bracket Replacement — figure 34
Fuel Injector Fuel Return Hose Bracket Replacement — figure 34
  1. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.
Fuel Injector Fuel Return Hose Bracket Replacement — figure 35
Fuel Injector Fuel Return Hose Bracket Replacement — figure 35
  1. Remove the 2 fuel feed pipe clip bolts (1).
Fuel Injector Fuel Return Hose Bracket Replacement — figure 36
Fuel Injector Fuel Return Hose Bracket Replacement — figure 36
  1. Remove the 2 fuel feed pipe clip bolts (1).
  2. Unclip the fuel injector fuel return pipe retainer (2).
Fuel Injector Fuel Return Hose Bracket Replacement — figure 37
Fuel Injector Fuel Return Hose Bracket Replacement — figure 37
  1. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.
  1. High Pressure Diesel Fuel Feed to Rail Pipe (2) » Remove and DISCARD
Fuel Injector Fuel Return Hose Bracket Replacement — figure 38
Fuel Injector Fuel Return Hose Bracket Replacement — figure 38
  1. Fuel Injection Fuel Feed Pipe Bracket Bolt (1) » Remove [2x]
  2. Fuel Injector Fuel Return Hose Bracket (2) » Remove Cleaning and Inspection Procedure - Required
Fuel Injector Fuel Return Hose Bracket Replacement — figure 39
Fuel Injector Fuel Return Hose Bracket Replacement — figure 39
  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.
Fuel Injector Fuel Return Hose Bracket Replacement — figure 40
Fuel Injector Fuel Return Hose Bracket Replacement — figure 40

  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. Fuel Injector Fuel Return Hose Bracket (2) » Install

  1. Fuel Injection Fuel Feed Pipe Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

  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.

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

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

  6. Install the 2 fuel feed pipe clip bolts (1) and tighten. Fastener Specifications

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

  8. 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

  9. Diesel Fuel Separator (1) » Install

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

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

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

  13. Front Wheelhouse Liner - Left Side » 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. 15. 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, then connect electrical connectors as needed.

  4. Charge Air Cooler Bracket (2) » Install

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

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

  7. Oil Filler Tube Support Stud (1) » Install and tighten — 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.

  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

Fuel Injector Fuel Return Hose Bracket Replacement — figure 41
Fuel Injector Fuel Return Hose Bracket Replacement — figure 41

  1. Exhaust Gas Recirculation Pipe Bolt (1) » Install and hand tighten

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

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

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

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

  6. Install the turbocharger coolant feed pipe bolt (3). Fastener Specifications

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

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

  9. Install and tighten the 3 engine wiring harness bracket nuts (1). Fastener Specifications

  10. Air Cleaner Outlet Duct (2) » Install

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

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

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

  14. Oil Filler Cap » Remove

  15. Intake Manifold Cover (2) » Install

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

  17. Oil Filler Cap » Install

  18. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

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

  20. Check for exhaust leak.