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Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Fuel Injector Copper Washers
    GM1335628Courtesy of GENERAL MOTORS CORP.
  1. If necessary, install a NEW O-ring onto the fuel injector.
  2. If necessary, install a NEW copper washer to the fuel injector bore.
  3. If necessary, install the fuel injector bracket pins.
    4. Fig 2: View Of Right Fuel Injectors W/Brackets
    GM1335625Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel injectors with brackets.
    5. Fig 3: View Of Right Fuel Injector Bracket Bolts
    GM1335619Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the fuel injector bracket bolts.

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

    6. Fig 4: View Of Fuel Injector Electrical Connectors
    GM1335536Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel injector electrical connectors.
    7. Fig 5: View Of Right Fuel Return Hose & Injectors
    GM1335592Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel return hose to the injectors.
  8. Install the fuel return hose clips.
    9. Fig 6: View Of Fuel Injector Pipes
    GM1335614Courtesy 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.
  9. Install the fuel injector pipes.

    Tighten:  Tighten the fittings to 41 N.m (30 lb ft).

  10. 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.
  11. Install the FICM. Refer to Fuel Injection Control Module Replacement .
  12. Install the fuel filter with bracket. Refer to Fuel Filter Replacement .
    13. Fig 7: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  13. Install the charged air cooler outlet duct from the intake.
  14. Tighten the charged air cooler outlet duct to intake hose clamp.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

  15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  16. Prime the fuel system. Refer to Fuel System Priming .
  17. Start the engine. If the engine stalls, repeat the above step.
  18. Once the engine starts, inspect for fuel leaks.
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