Fuel Injector Replacement Left Bank
Tools Required
• | EN-47909
Injector Bore and
Sleeve Cleaning Kit |
• | J 44639
Fuel Injector
Removal Tool |
Removal Procedure
Important: Refer to
Engine Controls Component Views
for fuel injector locations. Failure to identify
the correct cylinder will result in misdiagnosis.
- Remove the lower left valve rocker arm cover.
Refer to
Valve Rocker Arm Cover Replacement - Lower Left Side
in Engine Mechanical - 6.6L.
Important: When the fuel injector pressure lines are removed, debris may fall into
the fuel injector inlet fitting. Remove any debris from the inlet fitting of the fuel
injector.
Important: Confirm which side of the banjo washers
have the largest outer diameter.
- Remove the return line from the injectors.
- Remove the retaining bolt from the injector bracket.
- Install the
J 44639
(2) on the injector retainer bracket.
- Install a wrench on the
J 44639
(2) and pry away from the fuel injector (1).
- Remove the faulty injectors.
- Remove the copper compression washer from injection hole if the washer
did not remove with the injector.
Fuel Injector Cleaning and Inspection
Important: If reusing the old injectors perform the
following:
Notice: The fuel injector must be cleaned with the proper cleaning equipment.
DO NOT use abrasive cleaning methods, such as a metallic brush, to remove
deposits. Cleaning an injector with improper tools will damage the fuel injector.
- Use a soft bristle non-metallic brush and top engine cleaner, GM P/N 1052626
or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer
sealing area (2) before re-installation.
- Inspect the fuel injector nozzle tip (1) for any signs of discoloration
(dark yellow, tan, or blue) due to excessive heat.
- Replace the injector if any damage is found.
- Clean the fuel injector high pressure line.
- Inspect the fuel injector high pressure line for excessive corrosion or
damage to the sealing surfaces (1, 2). Replace the line if any damage is found.
Injector Bore Cleaning
Important: The procedure below will aid in the cleaning
of carbon deposits from the injector sleeve during an injector replacement
- Install the radial brush (brass) (EN-47909-2), to the handle
assembly (EN-47909-1).
- Insert the brush into the injector bore and rotate the handle in order
to break loose any carbon deposits from the injector bore walls and the combustion
deck hole.
Caution: Wear safety glasses in order to avoid eye damage.
- Using compressed air, evacuate any debris from the injector bore.
- Remove the radial brush from the handle assembly.
- Install the axial brush (nylon) (EN-47909-3), to the handle
assembly (EN-47909-1).
- Insert the axial brush into the injector bore and rotate the handle while
also applying a slight downward pressure, in order to force the brush ends into the
bottom corners of the injector bore.
Caution: Wear safety glasses in order to avoid eye damage.
- Using compressed air, evacuate any debris from the injector bore.
Notice: Do not allow excessive amounts of solvent to go into the cylinder during cleaning. Failure to do so may cause engine damage upon startup.
- Lightly dampen a cotton swab (EN-47909-20) with GM Top Engine
Cleaner, P/N 1052626 (Canadian P/N 993026) or equivalent, and
wipe away any deposits from the injector bore.
Important: DO NOT crank the engine in order to
expel any solvent from the cylinder. Cranking the engine with the injector removed
may cause the injector sleeve to unseat and fill the cylinder with engine coolant.
- Inspect the injector bore for any deposits and repeat brushing if necessary.
Installation Procedure
- If the injector sleeve was pulled from the
cylinder head when removing the injector(s), refer to
Fuel Injector Nozzle Tube Sleeve Replacement
in Engine Mechanical - 6.6L.
- Install a NEW O-ring onto the fuel injector(s).
- Lubricate the O-ring with clean engine oil.
- Install a NEW copper washer into the fuel injector bore in the cylinder
head.
- Install the fuel injector with injector bracket.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the injector bracket bolt.
Tighten
Tighten the bolt to 50 N·m (37 lb ft).
- Install the fuel injector return pipe assembly.
- Install the fuel injector return line to injector eye bolts and washers.
Lubricate the washers with diesel fuel prior to installing.
Tighten
Tighten the fuel injector return line to injector
eye bolts to 16 N·m (12 lb ft).
- Install the fuel injector return line to cylinder head eye bolts and washers.
Lubricate the washers with diesel fuel prior to installing.
Tighten
Tighten the fuel injector return line to cylinder
head eye bolts to 17 N·m (12 lb ft).
- Install the lower left valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement - Lower Left Side
in Engine Mechanical -
6.6L.
Fuel Injector Replacement Right Bank
Tools Required
• | EN-47909
Injector Bore and
Sleeve Cleaning Kit |
• | J 44639
Fuel Injector
Removal Tool |
Removal Procedure
Important: Refer to
Engine Controls Component Views
for fuel injector locations. Failure to identify
the correct cylinder will result in misdiagnosis.
- Remove the lower right valve rocker arm
cover. Refer to
Valve Rocker Arm Cover Replacement - Lower Right Side
in Engine Mechanical - 6.6L.
Important: When the fuel injector pressure lines are removed, debris may fall into
the fuel injector inlet fitting. Remove any debris from the inlet fitting of the fuel
injector.
Important: Confirm which side of the banjo washers
have the largest outer diameter.
- Remove the return line from the injectors.
- Remove the retaining bolt from the injector bracket.
- Install the
J 44639
(2) on the injector retainer bracket.
- Install a wrench on the
J 44639
(2) and pry away from the fuel injector (1).
- Remove the faulty injectors.
- Remove the copper compression washer from injection hole if the washer
did not remove with the injector.
Fuel Injector Cleaning and Inspection
Important: If reusing the old injectors perform the
following:
Notice: The fuel injector must be cleaned with the proper cleaning equipment.
DO NOT use abrasive cleaning methods, such as a metallic brush, to remove
deposits. Cleaning an injector with improper tools will damage the fuel injector.
- Use a soft bristle non-metallic brush and top engine cleaner, GM P/N 1052626
or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer
sealing area (2) before re-installation.
- Inspect the fuel injector nozzle tip (1) for any signs of discoloration
(dark yellow, tan, or blue) due to excessive heat.
- Replace the injector if any damage is found.
- Clean the fuel injector high pressure line.
- Inspect the fuel injector high pressure line for excessive corrosion or
damage to the sealing surfaces (1, 2). Replace the line if any damage is found.
Injector Bore Cleaning
Important: The procedure below will aid in the cleaning
of carbon deposits from the injector sleeve during an injector replacement
- Install the radial brush (brass) (EN-47909-2), to the handle
assembly (EN-47909-1).
- Insert the brush into the injector bore and rotate the handle in order
to break loose any carbon deposits from the injector bore walls and the combustion
deck hole.
Caution: Wear safety glasses in order to avoid eye damage.
- Using compressed air, evacuate any debris from the injector bore.
- Remove the radial brush from the handle assembly.
- Install the axial brush (nylon) (EN-47909-3), to the handle
assembly (EN-47909-1).
- Insert the axial brush into the injector bore and rotate the handle while
also applying a slight downward pressure, in order to force the brush ends into the
bottom corners of the injector bore.
Caution: Wear safety glasses in order to avoid eye damage.
- Using compressed air, evacuate any debris from the injector bore.
Notice: Do not allow excessive amounts of solvent to go into the cylinder during cleaning. Failure to do so may cause engine damage upon startup.
- Lightly dampen a cotton swab (EN-47909-20) with GM Top Engine
Cleaner, P/N 1052626 (Canadian P/N 993026) or equivalent, and
wipe away any deposits from the injector bore.
Important: DO NOT crank the engine in order to
expel any solvent from the cylinder. Cranking the engine with the injector removed
may cause the injector sleeve to unseat and fill the cylinder with engine coolant.
- Inspect the injector bore for any deposits and repeat brushing if necessary.
Installation Procedure
- If the injector sleeve is pulled from the
cylinder head when removing the injector(s), refer to
Fuel Injector Nozzle Tube Sleeve Replacement
in Engine Mechanical - 6.6L.
- Install a NEW O-ring onto the fuel injector(s).
- Lubricate the O-ring with clean engine oil.
- Install a NEW copper washer into the fuel injector bore in the cylinder
head.
- Install the fuel injector with injector bracket.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the injector bracket bolt.
Tighten
Tighten the fuel injector bracket bolt to 50 N·m
(37 lb ft).
- Install the fuel injector return pipe assembly.
- Install the fuel injector return line to injector eye bolts and washers.
Lubricate the washers with diesel fuel prior to installing.
Tighten
Tighten the fuel injector return line to injector
eye bolts to 16 N·m (12 lb ft).
- Install the fuel injector return line to cylinder head eye bolts and washers.
Lubricate the washers with diesel fuel prior to installing.
Tighten
Tighten the fuel injector return line to cylinder
head eye bolts to 17 N·m (12 lb ft).
- Install the lower right valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement - Lower Right Side
in Engine Mechanical -
6.6L.