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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Controls - 6.6L - 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. If necessary, install a NEW O-ring onto the fuel injector.
  2. If necessary, install a NEW copper washer to the fuel injector bore.
    Fig 1: Identifying Fuel Injector Copper Washers
    GM1335628Courtesy of GENERAL MOTORS CORP.
  3. If necessary, install the fuel injector bracket pins.
  4. Install the fuel injectors with brackets.
    Fig 2: View Of Left Fuel Injectors W/Brackets
    GM1335621Courtesy of GENERAL MOTORS CORP.
    5. NOTE: Refer to Fastener Notice .
    Fig 3: Installing Left Fuel Injector Bracket Bolts
    GM1335618Courtesy of GENERAL MOTORS CORP.
  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 Fuel Return Hose & Injectors
    GM1335588Courtesy 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 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.
  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 PCV hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .
    12. Fig 7: Connecting Glow Plug Control Module Electrical Connectors
    GM1653265Courtesy of GENERAL MOTORS CORP.
  12. Connect the glow plug control module electrical connector (1,2).
    13. Fig 8: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  13. Install the main electrical harness bracket.
  14. Install the main electrical harness bracket bolts.

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

  15. Connect the barometric sensor electrical connector.
  16. Install the engine wire harness to the clip.
  17. Install the main electrical connectors to the bracket.
  18. Install the engine harness main electrical connectors bolts.
    Fig 9: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.

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

    19. Fig 10: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  19. Connect the main engine electrical harness connectors.
  20. Push down on the latches (1) in order to connect the connectors.
  21. Close the harness clip (2).
  22. Remove the tape from the turbocharger openings.
  23. Install the charged air cooler inlet duct connector (4) to the turbocharger.
    Fig 11: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  24. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

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

  25. Fill the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) or Draining and Filling Cooling System (w/o RPO HP2) .
  26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  27. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  28. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming .
  29. Prime the fuel system. Refer to Fuel System Priming .
  30. Start the engine. If the engine stalls, repeat the above step.
  31. Once the engine starts, inspect for fuel leaks.
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