GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Express - AWD 🢒 Engine 🢒 Engine Mechanical - 6.6L 🢒 Fuel Injection Pump Replacement

Removal Procedure

    Object Number: 1335603 Size: SH
  1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
  2. Remove the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side.
  3. Remove the right fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side.
  4. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
  5. Disconnect the injection pump electrical connector.

    6. Object Number: 1335595 Size: SH
  6. Compress the injection pump hose clamps at the fuel line.
  7. Disconnect the hoses from fuel lines.

    8. Object Number: 1336114 Size: SH

    Note: Ensure to remove the top bolt at the rear of the pump.

  8. Remove the fuel injection pump bolts.

    9. Note: Be careful not to damage any mating surfaces.

  9. Remove the fuel injection pump from the block.

    10. Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight.

  10. The fuel injection pump may need to be rotated in order to remove it from the vehicle.

Preparing The Fuel Injection Pump
  1. Hold the fuel pump by the drive gear in a vice with copper jaw liners.
  2. Loosen the gear nut until the nut is even with the end of the gear shaft.
  3. Remove the gear from the tapered shaft of the injection pump.
  4. Separate the injection pump and adapter by removing the 3 bolts and spacers.
  5. Inspect the O-ring for damage on the pump adapter and replace, if necessary. Lubricate the O-ring with clean engine oil.
  6. Clean all mating surfaces.

    7. Caution: Refer to Fastener Caution in the Preface section.

  7. Install the adapter on the pump.
  8. Install the 3 bolts and spacers and tighten to 20 N·m (15 lb ft).
  9. Install the gear and nut and tighten to 70 N·m (52 lb ft).

Installation Procedure

    Object Number: 1336114 Size: SH
  1. Install the fuel injection pump to the block.
  2. Install the fuel injection pump bolts and tighten to 21 N·m (15 lb ft).
  3. Install the hoses to fuel lines.
  4. Position the injection pump hose clamps at the fuel line.
  5. Connect the injection pump electrical connector.
  6. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
  7. Install the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side.
  8. Install the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side.
  9. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.

    10. Object Number: 1601448 Size: SH
  10. Prime the fuel system. Refer to Fuel System Priming.
  11. Start the engine.

    12. If the engine stalls, repeat the above step.

  12. Once the engine starts, inspect for fuel leaks.