GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series Motorhome (Cutaway) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L (LLY) 🢒 Fuel Injection Pump Replacement

Removal Procedure

    Object Number: 652573 Size: SH
  1. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

    2. Important: After removing the outlet duct, cover the turbocharger (TC) openings with tape in order to prevent entry of objects.

  2. Remove the air cleaner . Refer to Air Cleaner Replacement .
  3. Remove the charged air pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
  4. Remove the fuel injection control module (FICM). Refer to Fuel Injector Control Module Replacement .
  5. Drain the cooling system. Refer to Cooling System Draining and Filling .
  6. Remove the fan. Refer to Fan Replacement .
  7. Disconnect the A/C compressor clutch electrical connector.
  8. Disconnect the A/C cut out switch electrical connector.
  9. Remove the A/C compressor bolts.
  10. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.

    11. Object Number: 1334867 Size: SH
  11. Remove the A/C compressor/power steering pump mounting bracket. Refer to Air Conditioning Compressor Replacement .
  12. Remove the oil fill tube. Refer to Oil Filler Tube Replacement for the 6.6L (LLY) engine.
  13. Remove the heater outlet hose bolt from the generator bracket.

    14. Object Number: 1334909 Size: SH
  14. Remove the drive belt tensioner bolt and tensioner.

    15. Object Number: 1334912 Size: SH
  15. Remove the generator. Refer to Generator Replacement .
  16. Remove the generator bracket bolts and bracket.
  17. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
  18. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .

    19. Object Number: 1335586 Size: SH
  19. Disconnect the fuel balance pipe fitting from the right fuel rail.
  20. Remove the fuel balance pipe retainer bolts.

    21. Object Number: 1335603 Size: SH
  21. Disconnect the fuel rail inlet pipe from the injection pump and rail.
  22. Remove the inlet pipe.
  23. Remove the center intake manifold. Refer to Center Intake Manifold Replacement .

    24. Object Number: 1335595 Size: SH
  24. Reposition the injection pump hose clamps at the fuel line.
  25. Remove the hoses from fuel lines.

    26. Object Number: 1336114 Size: SH
  26. Remove the fuel injection pump bolts.

    27. Important: Be careful not to damage any mating surfaces.

  27. Remove the fuel injection pump from the block.

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

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

Fuel Injection Pump Preparation Procedure
  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. Notice: Refer to Fastener Notice in the Preface section.

  7. Install the adapter on the pump.
  8. Install the 3 bolts and spacers.

    9. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  9. Install the gear and nut.

    10. Tighten
    Tighten nut 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.

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


    Object Number: 1335595 Size: SH
  3. Install the hoses to fuel lines.
  4. Position the injection pump hose clamps at the fuel line.
  5. Install the center intake manifold. Refer to Center Intake Manifold Replacement .

    6. Object Number: 1335603 Size: SH
  6. Install the inlet pipe.
  7. Connect the fuel rail inlet pipe to the injection pump and rail.

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


    Object Number: 1335586 Size: SH
  8. Connect the fuel balance pipe fitting to the right fuel rail.

    9. Tighten
    Tighten the fitting to 41 N·m (30 lb ft).

  9. Install the fuel balance pipe retainer bolts.

    10. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1334912 Size: SH
  10. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
  11. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
  12. Install the generator bracket and bolts.

    13. Tighten
    Tighten the bolts to 46 N·m (34 lb ft).

  13. Install the generator. Refer to Generator Replacement .

    14. Object Number: 1334909 Size: SH
  14. Install the drive belt tensioner and bolt.

    15. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).

  15. Install the heater outlet hose bolt to the generator bracket.

    16. Tighten
    Tighten the bolt to 21 N·m (15 lb ft).

  16. Install the oil fill tube. Refer to Oil Filler Tube Replacement for the 6.6L (LLY) engine.

    17. Object Number: 1334867 Size: SH
  17. Install the A/C compressor/power steering pump mounting bracket. Refer to Air Conditioning Compressor Replacement .

    18. Object Number: 652573 Size: SH
  18. Position the A/C compressor, with the hoses attached, to the bracket.
  19. Install the A/C compressor bolts.

    20. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  20. Connect the A/C cut out switch electrical connector.
  21. Connect the A/C compressor clutch electrical connector.
  22. Install the fan. Refer to Fan Replacement .
  23. Install the FICM. Refer to Fuel Injector Control Module Replacement .
  24. Fill the cooling system. Refer to Cooling System Draining and Filling .
  25. Install the charged air pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement for the 6.6L (LLY) engine.
  26. Connect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  27. Install the air cleaner . Refer to Air Cleaner Replacement .
  28. Prime the fuel system. Refer to Fuel System Priming .
  29. Start the engine. If the engine stalls, repeat the above step.
  30. Once the engine starts, inspect for fuel leaks.