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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Control System & Fuel System - 6.6L (LLY) - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Injector Replacement (Left) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Install a NEW copper washer to the fuel injector bore.
  2. Install a NEW fuel injector O-ring to the injector.
    3. Fig 1: View Of Left Fuel Injectors W/Brackets
    GM1335621Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel injectors with brackets.
    4. Fig 2: View Of Left Fuel Injector Bracket Bolts
    GM1335618Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  4. Install the fuel injector bracket bolts.

    Tighten:  Tighten the fuel injector bracket bolts to 30 N.m (22 lb ft).

    5. Fig 3: View Of Fuel Injector Engine Wiring Harness Electrical Connector
    GM1732433Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel injector electrical connectors.
    6. Fig 4: View Of Fuel Return Hose At The Fuel Injector
    GM1732415Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel return hose to the injectors.
    7. Fig 5: View Of Fuel Return Hose Clip At The Fuel Injector
    GM1732395Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel return hose clips (1).
    8. Fig 6: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.
  8. Install the left fuel injector pipes.

    Tighten:  Tighten the fuel injector pipes to 41 N.m (30 lb ft).

  9. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
    10. Fig 7: Identifying Engine Wiring Harness Bracket
    GM1732378Courtesy of GENERAL MOTORS CORP.
  10. Position the engine wiring harness bracket (1), install the engine wiring harness to bracket bolt and the 2 engine wiring harness bracket to upper valve cover bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

  11. Connect the left engine wiring main harness connector.
  12. Install the fuel feed/return line bracket and bolt located under glow plug module bracket.
  13. Install the injector/glow plug wire harness retaining bolt at the lower part of the upper valve cover.
  14. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement .
  15. If equipped, install the auxiliary generator. Refer to Auxiliary Generator Replacement .
  16. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L) or Engine Coolant Fan Upper Shroud Replacement (6.6L) .
  17. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming .
  18. Prime the fuel system. Refer to Fuel System Priming .
  19. Start the engine. If the engine stalls, repeat the above step.
  20. Once the engine starts, inspect for fuel leaks.
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