Removal & Installation

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Cover the air intake pipe end with duct tape to prevent the infiltration of dirt.

Disconnect negative battery cables from both batteries. Remove the air intake duct between the air cleaner and the turbocharger inlet housing. Drain the coolant. Remove the upper fan shroud. Remove the fan blade assembly. Remove the serpentine belt. Remove the bolt holding the positive battery cable junction box and bracket and move out of the way.

NOTE: Remove only the air conditioning/power steering bracket. Do not discharge the A/C or remove the A/C and power steering lines.

Remove the A/C compressor. See appropriate article in AIR CONDITIONING & HEATING. Remove the power steering pump. Position the A/C compressor and power steering pump aside. Remove the oil filler tube. Remove the air conditioning/power steering bracket. Remove the alternator. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts. Remove the Positive Crankcase Ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and reposition.
Remove the alternator bracket. Remove the turbo cooling hose return line clamp and hose. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way. Remove bolt holding wiring support bracket at thermostat housing. Move the main wiring harness by disconnecting the fuel pressure regulator connector on the fuel injection pump and the fuel injection control module connectors. Flip the wire harness and harness tray towards the back and set aside. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing.

NOTE: Cap all of the open fuel connections with suitable plastic plugs in order to prevent infiltration of dirt.

Remove the air intake pipe. Remove the thermostat crossover assembly. Remove the hose to the turbo water feed line. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and function block.
Remove the high pressure line from the injection pump to the junction block. Remove the fuel return hose from fuel injection pump. Remove the high pressure line from the injection pump to the junction block. Remove fuel injection pump from the block using two screwdrivers to work the pump from the block towards rear of engine keeping the pump straight. Remove fuel injection pump. See Fig 1.
To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Fig 1: Removing Fuel Injection Pump (6.6L)

Courtesy of GENERAL MOTORS CORP.