Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 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.  

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.  

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.  

 
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