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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 (Right) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  2. Using a pick or a small flat-bladed screw driver, remove and discard the quick connect fitting clip from the charged air cooler outlet duct.
  3. Remove the charged air cooler outlet duct from the intake.
    Fig 1: Removing Charged Air Cooler Outlet Duct
    GM1653035Courtesy of GENERAL MOTORS CORP.
  4. Remove the fuel filter and bracket. Refer to Fuel Filter Replacement .
  5. Remove the wiring harness retainer from the bracket.
  6. Remove the oil level indicator tube bolt.
  7. Remove the oil level indicator tube bracket bolts.
    Fig 2: Removing Tube Bracket Bolts
    GM1601448Courtesy of GENERAL MOTORS CORP.
  8. Remove the bracket.
  9. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
  10. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    11. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.
    Fig 3: View Of Fuel Injector Pipes
    GM1335614Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel injector pipes.
  12. Remove the fuel return hose clips.
  13. Remove the fuel return hose from the injectors.
    Fig 4: View Of Right Fuel Return Hose & Injectors
    GM1335592Courtesy of GENERAL MOTORS CORP.
    14. NOTE: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.
    Fig 5: View Of Fuel Injector Electrical Connectors
    GM1335536Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the fuel injector electrical connectors.
  15. Remove the fuel injector bracket bolts.
    Fig 6: Removing Right Fuel Injector Bracket Bolts
    GM1335619Courtesy of GENERAL MOTORS CORP.
  16. Install J-46594  into the bolt hole in the fuel injector bracket.
  17. Install a flare nut wrench onto J-46594  and pull back away from the fuel injector, until the injector releases from its seat.
  18. Remove J-46594  .
  19. Remove the fuel injectors with brackets.
    Fig 7: View Of Right Fuel Injectors W/Brackets
    GM1335625Courtesy of GENERAL MOTORS CORP.
  20. If necessary, remove the fuel injector bracket pins.
  21. If necessary, remove and discard the copper washer from the fuel injector bore.
    Fig 8: Identifying Fuel Injector Copper Washers
    GM1335628Courtesy of GENERAL MOTORS CORP.
  22. If necessary, remove and discard the O-ring from the fuel injector.
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