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

Injection Pump

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All vehicles are equipped with an electronically controlled pump. The electronic pump is driven by gears and rotates at the same speed as the camshaft. An electronic stepper motor used to control injection timing and a fuel solenoid driver used to control the fuel injection solenoid on the electronic model.

All vehicles are equipped with an electronically controlled pump. The electronic pump is driven by gears and rotates at the same speed as the camshaft. An electronic stepper motor used to control injection timing and a fuel solenoid driver used to control the fuel injection solenoid on the electronic model.

All vehicles are equipped with an electronically controlled pump. The electronic pump is driven by gears and rotates at the same speed as the camshaft. An electronic stepper motor used to control injection timing and a fuel solenoid driver used to control the fuel injection solenoid on the electronic model.

All vehicles are equipped with an electronically controlled pump. The electronic pump is driven by gears and rotates at the same speed as the camshaft. An electronic stepper motor used to control injection timing and a fuel solenoid driver used to control the fuel injection solenoid on the electronic model.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not engage the starter in order to rotate the engine with the injection pump removed. The pump driven gear could jam in the front housing resulting in a sheared crankshaft or camshaft gear key and possible valvetrain damage.



    Negative battery cables
     
    Intake manifold
     
    Fuel injection and inlet lines
     
    Cables wires, and hoses at the injection pump
     
    Fuel return line at the top of the injection pump
     
    Fuel feed line at the injection pump, if necessary
     
    Oil filler tube grommet
     

  6.  
  7. Scribe or paint a matchmark on the front cover and the injection pump flange.
  8.  
  9. Rotate the crankshaft by hand and remove the injection pump driven gear bolts, accessing the bolts through the oil filler neck hole.
  10.  
  11. Remove the injection pump-to-front cover attaching nuts. Remove the pump. Be sure to cap all open lines and nozzles in order to prevent system contamination and damage.
  12.  

To install:

Click image to see an enlarged view

Fig. Align the pin on the pump hub with the slot in the driven gear, NOT into the hole in the gear-diesel engines

  1. Align the locating pin on the pump hub with the slot in the injection pump driven gear (the SLOT not the hole in the gear) At the same time, align the timing marks.
  2.  
  3. Attach the injection pump to the front cover. Torque the nuts to 30 ft. lbs. (40 Nm) checking the timing marks before tightening.
  4.  
  5. Install or connect the following:

    Driven gear-to-injection pump bolts. Torque the bolts to 20 ft. lbs. (25 Nm).
     
    Grommet and oil fill tube
     
    Air conditioning bracket. If applicable
     
    Fuel feed line. Torque to 20 ft. lbs. (25 Nm).
     
    Fuel return line to the pump, if removed
     
    Cables, wires and hoses previously removed
     
    Injector lines
     
    Intake manifold
     
    Negative battery cables
     

  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Drain the cooling system
  2.  
  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.
     
    Alternator
     
    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
     

  4.  
  5. Move the main wiring harness by disconnecting the following:
    1. The fuel pressure regulator connector on the fuel injection pump
    2.  
    3. Fuel injection control module connectors
    4.  

  6.  
  7. Flip the wire harness and harness tray toward the back and position aside.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Cap all open fuel connections to prevent contaminants from entering.


    NOTE
    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

     

  10.  
  11. Prepare the fuel pump as follows:
    1. Hold the fuel pump by the drive gear in a vise with copper jaw liners.
    2.  
    3. Loosen the gear nut until the nut is even with the end of the gear shaft.
    4.  
    5. Separate the pump and adapter by removing the 3 bolts and spacers.
    6.  
    7. Inspect the O-ring for damage on the pump adapter and replace if necessary. Lubricate the O-ring with clean engine oil.
    8.  
    9. Clean all mating surfaces.
    10.  
    11. Install the adapter on the pump
    12.  
    13. Using the bolts and spacers, reassemble the pump. Tighten the bolts to 15 ft. lbs. (20 Nm).
    14.  
    15. Install the gear and nut and tighten to 52 ft. lbs. (70 Nm).
    16.  

  12.  

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)
     

  2.  
  3. Refill the cooling system, then start the engine and check for leaks.
  4.  

  1. Drain the cooling system
  2.  
  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.
     
    Alternator
     
    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
     

  4.  
  5. Move the main wiring harness by disconnecting the following:
    1. The fuel pressure regulator connector on the fuel injection pump
    2.  
    3. Fuel injection control module connectors
    4.  

  6.  
  7. Flip the wire harness and harness tray towards the back and position aside.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Cap all open fuel connections to prevent contaminants from entering.


    NOTE
    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

     

  10.  
  11. Prepare the fuel pump as follows:
    1. Hold the fuel pump by the drive gear in a vise with copper jaw liners.
    2.  
    3. Loosen the gear nut until the nut is even with the end of the gear shaft.
    4.  
    5. Separate the pump and adapter by removing the 3 bolts and spacers.
    6.  
    7. Inspect the O-ring for damage on the pump adapter and replace if necessary. Lubricate the O-ring with clean engine oil.
    8.  
    9. Clean all mating surfaces.
    10.  
    11. Install the adapter on the pump
    12.  
    13. Using the bolts and spacers, reassemble the pump. Tighten the bolts to 15 ft. lbs. (20 Nm).
    14.  
    15. Install the gear and nut and tighten to 52 ft. lbs. (70 Nm).
    16.  

  12.  

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)
     

  2.  
  3. Refill the cooling system, then start the engine and check for leaks.
  4.  

6.5L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not engage the starter in order to rotate the engine with the injection pump removed. The pump driven gear could jam in the front housing resulting in a sheared crankshaft or camshaft gear key and possible valve train damage.



    Negative battery cables
     
    Intake manifold
     
    Fuel injection and inlet lines
     
    Cables wires, and hoses at the injection pump
     
    Fuel return line at the top of the injection pump
     
    Fuel feed line at the injection pump, if necessary
     
    Oil filler tube grommet
     

  4.  
  5. Scribe or paint a matchmark on the front cover and the injection pump flange.
  6.  
  7. Rotate the crankshaft by hand and remove the injection pump driven gear bolts, accessing the bolts through the oil filler neck hole.
  8.  
  9. Remove the injection pump-to-front cover attaching nuts. Remove the pump. Be sure to cap all open lines and nozzles in order to prevent system contamination and damage.
  10.  

To install:

Click image to see an enlarged view

Fig. Align the pin on the pump hub with the slot in the driven gear, NOT into the hole in the gear-diesel engines

  1. Align the locating pin on the pump hub with the slot in the injection pump driven gear (the SLOT not the hole in the gear) At the same time, align the timing marks.
  2.  
  3. Attach the injection pump to the front cover. Torque the nuts to 30 ft. lbs. (40 Nm) checking the timing marks before tightening.
  4.  
  5. Install or connect the following:

    Driven gear-to-injection pump bolts and tighten to 20 ft. lbs. (27 Nm)
     
    Grommet and oil fill tube
     
    Air conditioning bracket, if applicable
     
    Fuel feed line. Torque to 20 ft. lbs. (27 Nm).
     
    Fuel return line to the pump, if removed
     
    Cables, wires and hoses previously removed
     
    Injector lines
     
    Intake manifold
     
    Negative battery cables
     

  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not engage the starter in order to rotate the engine with the injection pump removed. The pump driven gear could jam in the front housing resulting in a sheared crankshaft or camshaft gear key and possible valvetrain damage.



    Negative battery cables
     
    Intake manifold
     
    Fuel injection and inlet lines
     
    Cables wires, and hoses at the injection pump
     
    Fuel return line at the top of the injection pump
     
    Fuel feed line at the injection pump, if necessary
     
    Oil filler tube grommet
     

  6.  
  7. Scribe or paint a matchmark on the front cover and the injection pump flange.
  8.  
  9. Rotate the crankshaft by hand and remove the injection pump driven gear bolts, accessing the bolts through the oil filler neck hole.
  10.  
  11. Remove the injection pump-to-front cover attaching nuts. Remove the pump. Be sure to cap all open lines and nozzles in order to prevent system contamination and damage.
  12.  

To install:

Click image to see an enlarged view

Fig. Align the pin on the pump hub with the slot in the driven gear, NOT into the hole in the gear-diesel engines

  1. Align the locating pin on the pump hub with the slot in the injection pump driven gear (the SLOT not the hole in the gear) At the same time, align the timing marks.
  2.  
  3. Attach the injection pump to the front cover. Torque the nuts to 30 ft. lbs. (40 Nm) checking the timing marks before tightening.
  4.  
  5. Install or connect the following:

    Driven gear-to-injection pump bolts. Torque the bolts to 20 ft. lbs. (25 Nm).
     
    Grommet and oil fill tube
     
    Air conditioning bracket. If applicable
     
    Fuel feed line. Torque to 20 ft. lbs. (25 Nm).
     
    Fuel return line to the pump, if removed
     
    Cables, wires and hoses previously removed
     
    Injector lines
     
    Intake manifold
     
    Negative battery cables
     

  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Do not engage the starter in order to rotate the engine with the injection pump removed. The pump driven gear could jam in the front housing resulting in a sheared crankshaft or camshaft gear key and possible valvetrain damage.



    Negative battery cables
     
    Intake manifold
     
    Fuel injection and inlet lines
     
    Cables wires, and hoses at the injection pump
     
    Fuel return line at the top of the injection pump
     
    Fuel feed line at the injection pump, if necessary
     
    Oil filler tube grommet
     

  6.  
  7. Scribe or paint a matchmark on the front cover and the injection pump flange.
  8.  
  9. Rotate the crankshaft by hand and remove the injection pump driven gear bolts, accessing the bolts through the oil filler neck hole.
  10.  
  11. Remove the injection pump-to-front cover attaching nuts. Remove the pump. Be sure to cap all open lines and nozzles in order to prevent system contamination and damage.
  12.  

To install:

Click image to see an enlarged view

Fig. Align the pin on the pump hub with the slot in the driven gear, NOT into the hole in the gear-diesel engines

  1. Align the locating pin on the pump hub with the slot in the injection pump driven gear (the SLOT not the hole in the gear) At the same time, align the timing marks.
  2.  
  3. Attach the injection pump to the front cover. Torque the nuts to 30 ft. lbs. (40 Nm) checking the timing marks before tightening.
  4.  
  5. Install or connect the following:

    Driven gear-to-injection pump bolts. Torque the bolts to 20 ft. lbs. (25 Nm).
     
    Grommet and oil fill tube
     
    Air conditioning bracket. If applicable
     
    Fuel feed line. Torque to 20 ft. lbs. (25 Nm).
     
    Fuel return line to the pump, if removed
     
    Cables, wires and hoses previously removed
     
    Injector lines
     
    Intake manifold
     
    Negative battery cables
     

  6.  
  7. Start the engine and check for leaks.
  8.  

6.6L Engine
  1. Drain the cooling system
  2.  
  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.
     
    Alternator
     
    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
     

  4.  
  5. Move the main wiring harness by disconnecting the following:
    1. The fuel pressure regulator connector on the fuel injection pump
    2.  
    3. Fuel injection control module connectors
    4.  

  6.  
  7. Flip the wire harness and harness tray towards the back and position aside.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Cap all open fuel connections to prevent contaminants from entering.


    NOTE
    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 engine

     

  10.  
  11. Prepare the fuel pump as follows:
    1. Hold the fuel pump by the drive gear in a vise with copper jaw liners.
    2.  
    3. Loosen the gear nut until the nut is even with the end of the gear shaft.
    4.  
    5. Separate the pump and adapter by removing the 3 bolts and spacers.
    6.  
    7. Inspect the O-ring for damage on the pump adapter and replace if necessary. Lubricate the O-ring with clean engine oil.
    8.  
    9. Clean all mating surfaces.
    10.  
    11. Install the adapter on the pump
    12.  
    13. Using the bolts and spacers, reassemble the pump. Tighten the bolts to 15 ft. lbs. (20 Nm).
    14.  
    15. Install the gear and nut and tighten to 52 ft. lbs. (70 Nm).
    16.  

  12.  

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)
     

  2.  
  3. Refill the cooling system, then start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system
  4.  
  5. Remove or disconnect the following:

    Negative battery cables
     
    Air intake duct. Cover the end to prevent dirt from entering
     
    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
     
    Alternator
     
    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
     

  6.  
  7. Move the main wiring harness by disconnecting:
    1. The fuel pressure regulator connector on the fuel injection pump
    2.  
    3. Fuel injection control module connectors
    4.  

  8.  
  9. Flip the wire harness and harness tray towards the back and position aside.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Cap all open fuel connections to prevent contaminants from entering.


    NOTE
    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 prytools 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 engine

     

  12.  
  13. Prepare the fuel pump as follows:
    1. Hold the fuel pump by the drive gear in a vice with copper jaw liners.
    2.  
    3. Loosen the gear nut until the nut is even with the end of the gear shaft.
    4.  
    5. Separate the pump and adapter by removing the 3 bolts and spacers.
    6.  
    7. Inspect the O-ring for damage on the pump adapter and replace if necessary. Lubricate the O-ring with clean engine oil.
    8.  
    9. Clean all mating surfaces.
    10.  
    11. Install the adapter on the pump
    12.  
    13. Using the bolts and spacers, reassemble the pump. Tighten the bolts to 15 ft. lbs. (20 Nm).
    14.  
    15. Install the gear and nut and tighten to 52 ft. lbs. (70 Nm).
    16.  

  14.  

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)
     

  2.  
  3. Refill the cooling system, then start the engine and check for leaks.
  4.  

 
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