Sierra, Silverado 2006-2007

Injection Pump


Removal & Installation

  1. Drain the cooling system
  3. Remove or disconnect the following:

    Negative battery cables
    Air intake duct. Cover the end to prevent dirt from entering
    Intake manifold cover
    Fuel fill cap in order to relieve the fuel pressure
    Fuel Injection Control Module (FICM) electrical connectors
    Fuel injection control module
    Upper fan shroud
    Fan blade assembly
    Drive belt
    Bolt holding the positive battery cable junction box and bracket and position aside
    A/C compressor and power steering pump and position aside with the lines attached
    Oil dipstick tube
    A/C and power steering pump bracket
    Drive belt tensioner and bolt.
    Thermostat housing bracket, wiring and fuel test port and 2 nuts
    Positive Crankcase Ventilation (PCV) catch tank from the PCV bracket and the bolt below holding the lower line, then position aside
    Alternator bracket
    Turbo cooling hose return line clamp and hose
    Upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover and swing out of the way
    Bolt holding the wiring support bracket at the thermostat housing

  5. Move the main wiring harness by disconnecting the following:
    1. The fuel pressure regulator connector on the fuel injection pump
    3. Fuel injection control module connectors

  7. Flip the wire harness and harness tray towards the back and position aside.
  9. Remove or disconnect the following:
    Cap all open fuel connections to prevent contaminants from entering.

    When removing the pump, be careful not to damage any of the mating surfaces.

    Heater pipe bolt and temperature sensor wire from the thermostat housing
    Air intake pipe
    Water crossover assembly
    Hose from the turbo water feed line

    High pressure fuel lines and support pipe and hose at the fuel injection pump and junction block
    Fuel return hose from the fuel injection pump
    Y-junction banjo fitting from the junction block
    Bolts securing the fuel injection pump at the front cover and block

    Fuel injection pump from the block using 2 pry tools to work the pump from the block toward the rear of the engine, keeping the pump straight.

    Click image to see an enlarged view

    Fig. Diesel fuel injection pump-6.6L engines


  11. Prepare the fuel pump as follows:
    1. Hold the fuel pump by the drive gear in a vise with copper jaw liners.
    3. Loosen the gear nut until the nut is even with the end of the gear shaft.
    5. Separate the pump and adapter by removing the 3 bolts and spacers.
    7. Inspect the O-ring for damage on the pump adapter and replace if necessary. Lubricate the O-ring with clean engine oil.
    9. Clean all mating surfaces.
    11. Install the adapter on the pump
    13. Using the bolts and spacers, reassemble the pump. Tighten the bolts to 15 ft. lbs. (20 Nm).
    15. Install the gear and nut and tighten to 52 ft. lbs. (70 Nm).


To install:

  1. Installation is the reverse of removal, noting the following tightening specifications:

    Fuel injection pump mounting bolts: 15 ft. lbs. (20 Nm)
    Y-junction banjo fitting: 11 ft. lbs. (15 Nm)
    High pressure fuel lines: 40 ft. lbs. (54 Nm)
    Heater pipe bracket and water crossover bolts: 15 ft. lbs. (20 Nm)
    Upper radiator hose mounting bolts: 89 inch lbs. (10 Nm)
    A/C and power steering pump bracket bolts: 34 ft. lbs. (46 Nm)

  3. Refill the cooling system, then start the engine and check for leaks.