Sierra, Silverado 2006-2007

Injectors

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Removal & Installation




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.  

 
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