Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Injectors

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    Special tool J-29873, or its equivalent, an injection nozzle socket, will be necessary for this procedure.

  2.  
  3. Remove or disconnect the following:

    Batteries.
     
    Fuel line clip
     
    Fuel return hose
     
    Fuel injection lines
     

  4.  
  5. Using GM special tool J-29873, remove the injector. Always remove the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector. Always cap the injector and fuel lines when disconnected, to prevent contamination.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector nozzle.

  6.  

To install:

  1. Always install the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector.
  2.  
  3. Install or connect the following:

    Injector with a new gasket. Torque to 50 ft. lbs. (70 Nm).
     
    Injection line. Torque the nut to 20 ft. lbs. (25 Nm).
     
    Fuel return hose
     
    Fuel line clips
     
    Batteries
     

  4.  


NOTE
Special tool J-46594, or equivalent, an injector removal tool, will be necessary for this procedure.

  1. Drain the cooling system.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On the left side, remove the charged air cooler inlet duct connector from the turbocharger.
  6.  
  7. Remove the main engine electrical harness connectors.
  8.  
  9. Disconnect the barometric sensor electrical connector.
  10.  
  11. Remove the engine wire harness from the clip.
  12.  
  13. Remove the main electrical harness bracket bolts and bracket.
  14.  
  15. Disconnect the glow plug controller electrical connector.
  16.  
  17. Remove the positive crankcase ventilation (PCV) hose/pipe.
  18.  
  19. On the right side, remove the air cleaner outlet duct.
  20.  
  21. Loosen the charged air cooler outlet duct to intake hose clamp.
  22.  
  23. Remove the charged air cooler outlet duct from the intake.
  24.  
  25. Remove the fuel filter and bracket.
  26.  
  27. Remove the fuel injection control module.
  28.  
  29. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
  30.  
  31. Remove the fuel injector pipes.
  32.  
  33. Remove the fuel return hose from the injectors.
  34.  
  35. Disconnect the fuel injector electrical connectors.
  36.  
  37. Remove the fuel injector bracket bolts.
  38.  
  39. Install the injector removal tool J-46594 into the bolt hole in the fuel injector bracket.
  40.  
  41. Install a flare nut wrench onto the tool and pull back away from the fuel injector, until the injector releases from its seat.
  42.  
  43. Remove the tool.
  44.  
  45. Remove the fuel injectors with brackets.
  46.  
  47. If necessary, remove the fuel injector bracket pins.
  48.  
  49. If necessary, remove and discard the copper washer from the fuel injector bore.
  50.  
  51. If necessary, remove and discard the O-ring from the fuel injector.
  52.  

To install:

  1. If necessary, install a new O-ring onto the fuel injector.
  2.  
  3. If necessary, install a new copper washer to the fuel injector bore.
  4.  
  5. If necessary, install the fuel injector bracket pins.
  6.  
  7. Install the fuel injectors with brackets.
  8.  
  9. Install the fuel injector bracket bolts and tighten to 22 ft. lbs. (30 Nm).
  10.  
  11. Connect the fuel injector electrical connectors.
  12.  
  13. Install the fuel return hose to the injectors.
  14.  
  15. Install the fuel return hose clips.
  16.  
  17. Install the fuel injector pipes and tighten to 30 ft. lbs. (40 Nm).
  18.  
  19. On the left side, install the positive crankcase ventilation (PCV) hose/pipe.
  20.  
  21. Connect the glow plug controller electrical connector.
  22.  
  23. Install the main electrical harness bracket bolts and bracket.
  24.  
  25. Install the engine wire harness to the clip.
  26.  
  27. Connect the barometric sensor electrical connector.
  28.  
  29. Install the main engine electrical harness connectors.
  30.  
  31. Install the charged air cooler inlet duct connector to the turbocharger.
  32.  
  33. On the right side, install the fuel injection control module.
  34.  
  35. Install the fuel filter and bracket.
  36.  
  37. Install the charged air cooler outlet duct to the intake.
  38.  
  39. Tighten the charged air cooler outlet duct to intake hose clamp.
  40.  
  41. Install the air cleaner outlet duct.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Refill the cooling system.
  46.  


NOTE
Special tool J-46594, or equivalent, an injector removal tool, will be necessary for this procedure.

  1. Drain the cooling system.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. On the left side, remove the charged air cooler inlet duct connector from the turbocharger.
  6.  
  7. Remove the main engine electrical harness connectors.
  8.  
  9. Disconnect the barometric sensor electrical connector.
  10.  
  11. Remove the engine wire harness from the clip.
  12.  
  13. Remove the main electrical harness bracket bolts and bracket.
  14.  
  15. Disconnect the glow plug controller electrical connector.
  16.  
  17. Remove the positive crankcase ventilation (PCV) hose/pipe.
  18.  
  19. On the right side, remove the air cleaner outlet duct.
  20.  
  21. Loosen the charged air cooler outlet duct to intake hose clamp.
  22.  
  23. Remove the charged air cooler outlet duct from the intake.
  24.  
  25. Remove the fuel filter and bracket.
  26.  
  27. Remove the fuel injection control module.
  28.  
  29. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
  30.  
  31. Remove the fuel injector pipes.
  32.  
  33. Remove the fuel return hose from the injectors.
  34.  
  35. Disconnect the fuel injector electrical connectors.
  36.  
  37. Remove the fuel injector bracket bolts.
  38.  
  39. Install the injector removal tool J-46594 into the bolt hole in the fuel injector bracket.
  40.  
  41. Install a flare nut wrench onto the tool and pull back away from the fuel injector, until the injector releases from its seat.
  42.  
  43. Remove the tool.
  44.  
  45. Remove the fuel injectors with brackets.
  46.  
  47. If necessary, remove the fuel injector bracket pins.
  48.  
  49. If necessary, remove and discard the copper washer from the fuel injector bore.
  50.  
  51. If necessary, remove and discard the O-ring from the fuel injector.
  52.  

To install:

  1. If necessary, install a new O-ring onto the fuel injector.
  2.  
  3. If necessary, install a new copper washer to the fuel injector bore.
  4.  
  5. If necessary, install the fuel injector bracket pins.
  6.  
  7. Install the fuel injectors with brackets.
  8.  
  9. Install the fuel injector bracket bolts and tighten to 22 ft. lbs. (30 Nm).
  10.  
  11. Connect the fuel injector electrical connectors.
  12.  
  13. Install the fuel return hose to the injectors.
  14.  
  15. Install the fuel return hose clips.
  16.  
  17. Install the fuel injector pipes and tighten to 30 ft. lbs. (40 Nm).
  18.  
  19. On the left side, install the positive crankcase ventilation (PCV) hose/pipe.
  20.  
  21. Connect the glow plug controller electrical connector.
  22.  
  23. Install the main electrical harness bracket bolts and bracket.
  24.  
  25. Install the engine wire harness to the clip.
  26.  
  27. Connect the barometric sensor electrical connector.
  28.  
  29. Install the main engine electrical harness connectors.
  30.  
  31. Install the charged air cooler inlet duct connector to the turbocharger.
  32.  
  33. On the right side, install the fuel injection control module.
  34.  
  35. Install the fuel filter and bracket.
  36.  
  37. Install the charged air cooler outlet duct to the intake.
  38.  
  39. Tighten the charged air cooler outlet duct to intake hose clamp.
  40.  
  41. Install the air cleaner outlet duct.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Refill the cooling system.
  46.  

6.5L Engine

NOTE
Special tool J-29873, or its equivalent, an injection nozzle socket, will be necessary for this procedure.

  1. Remove or disconnect the following:

    Batteries.
     
    Fuel line clip(s)
     
    Fuel return hose
     
    Fuel injection lines
     

  2.  
  3. Using GM special tool J-29873, remove the injector. Always remove the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector. Always cap the injector and fuel lines when disconnected, to prevent contamination.

    Click image to see an enlarged view

    Fig. View of the fuel injector nozzle.

  4.  

To install:

  1. Always install the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector.
  2.  
  3. Install or connect the following:

    Injector with a new gasket. Torque to 50 ft. lbs. (70 Nm).
     
    Injection line. Torque the nut to 20 ft. lbs. (25 Nm).
     
    Fuel return hose
     
    Fuel line clip(s)
     
    Batteries
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    Special tool J-29873, or its equivalent, an injection nozzle socket, will be necessary for this procedure.

  2.  
  3. Remove or disconnect the following:

    Batteries.
     
    Fuel line clip
     
    Fuel return hose
     
    Fuel injection lines
     

  4.  
  5. Using GM special tool J-29873, remove the injector. Always remove the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector. Always cap the injector and fuel lines when disconnected, to prevent contamination.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector nozzle.

  6.  

To install:

  1. Always install the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector.
  2.  
  3. Install or connect the following:

    Injector with a new gasket. Torque to 50 ft. lbs. (70 Nm).
     
    Injection line. Torque the nut to 20 ft. lbs. (25 Nm).
     
    Fuel return hose
     
    Fuel line clips
     
    Batteries
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    Special tool J-29873, or its equivalent, an injection nozzle socket, will be necessary for this procedure.

  2.  
  3. Remove or disconnect the following:

    Batteries.
     
    Fuel line clip
     
    Fuel return hose
     
    Fuel injection lines
     

  4.  
  5. Using GM special tool J-29873, remove the injector. Always remove the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector. Always cap the injector and fuel lines when disconnected, to prevent contamination.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector nozzle.

  6.  

To install:

  1. Always install the injector by turning the 30mm hex portion of the injector; turning the round portion will damage the injector.
  2.  
  3. Install or connect the following:

    Injector with a new gasket. Torque to 50 ft. lbs. (70 Nm).
     
    Injection line. Torque the nut to 20 ft. lbs. (25 Nm).
     
    Fuel return hose
     
    Fuel line clips
     
    Batteries
     

  4.  

6.6L Engine

NOTE
Special tool J 44639, or equivalent, an injector removal tool, will be necessary for this procedure.

  1. Remove or disconnect the following:

    Negative battery cables
     
    Lower valve cover
     
    Spill line from the injectors
     
    Retainer bolt from the injector bracket
     

  2.  
  3. Install the fuel injector removal tool onto the injector retainer bracket.
    NOTE
    Check to see which side of the banjo washers have the largest hole.

  4.  
  5. Install a wrench on the fuel injector removal tool and pry away from the injector.
  6.  
  7. Remove the faulty injectors.
  8.  
  9. Remove the copper compression washer from the injection hole if the washer did not come off with the injector.
  10.  

To install:

  1. If the injector sleeve is pulled from the cylinder head when removing the injector, the injector sleeve must be installed as follows:
    1. Set the new injector sleeve gaskets to the injector sleeve.
    2.  
    3. Apply threadlock to the lower sealing area of the injector sleeve.
    4.  
    5. Use a large brass drift to drive the injector sleeve into the cylinder head until fully seated.
    6.  

  2.  
  3. Replace the copper compression washer. Assembly grease may be needed to hold the washer in place.
  4.  
  5. Install or connect the following:

    New injectors
     
    Retainer bolt on the injector bracket. Tighten to 36 ft. lbs. (46 Nm).
     
    Spill line and tighten the bolts to 108 inch lbs. (12 Nm)
     
    Lower valve cover
     
    Negative battery cables
     

  6.  

The following procedure is for the left or right bank fuel injector replacement.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    Special tool J 44639, or its equivalent, an injector removal tool, will be necessary for this procedure.

  2.  
  3. Remove or disconnect the following:

    Negative battery cables.
     
    Lower valve cover
     
    Spill line from the injectors
     
    Retainer bolt from the injector bracket
     

  4.  
  5. Install the fuel injector removal tool onto the injector retainer bracket.
    NOTE
    Check to see which side of the banjo washers have the largest hole.

  6.  
  7. Install a wrench on the fuel injector removal tool and pry away from the injector.
  8.  
  9. Remove the faulty injectors.
  10.  
  11. Remove the copper compression washer from the injection hole if the washer did not come off with the injector.
  12.  

To install:

  1. If the injector sleeve is pulled from the cylinder head when removing the injector, the injector sleeve must be installed as follows:
    1. Set the new injector sleeve gaskets to the injector sleeve.
    2.  
    3. Apply threadlock to the lower sealing area of the injector sleeve.
    4.  
    5. Use a large brass drift to drive the injector sleeve into the cylinder head until fully seated.
    6.  

  2.  
  3. Replace the copper compression washer. Assembly grease may be needed to hold the washer in place.
  4.  
  5. Install or connect the following:

    New injectors
     
    Retainer bolt on the injector bracket. Tighten to 36 ft. lbs. (46 Nm).
     
    Spill line and tighten the bolts to 108 inch lbs. (12 Nm)
     
    Lower valve cover
     
    Negative battery cables
     

  6.  

 
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