GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2009 🢒 Sierra Denali 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Injection Pump Replacement

Removal Procedure

    Object Number: 1872010 Size: SH
  1. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
  2. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
  3. Reposition the fuel hose clamp (1) at the fuel return pipe.
  4. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold.

    5. Object Number: 1872011 Size: SH
  5. Reposition the fuel hose clamp (2) at the fuel injection pump.
  6. Reposition the fuel hose clamp (3) at the fuel injection pump.
  7. Remove the fuel hose (1) from the return pipe and injection pump.
  8. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump.

    9. Object Number: 1387871 Size: SH
  9. Loosen the left fuel rail fuel feed pipe fittings (1).

    10. Object Number: 1335603 Size: SH
  10. Remove the left fuel rail fuel feed pipe.

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

  11. Remove the fuel injection pump. Refer to Fuel Injection Pump Removal.

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.

    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
  1. Install the fuel injection pump. Refer to Fuel Injection Pump Installation.

    2. Object Number: 1335603 Size: SH
  2. Position the left fuel rail fuel feed pipe.

    3. Object Number: 1387871 Size: SH
  3. Tighten the left fuel rail fuel feed pipe fittings (1).

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


    Object Number: 1872011 Size: SH
  4. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump.
  5. Install the fuel hose (1) from the return pipe and injection pump.
  6. Position the fuel hose clamp (3) at the fuel injection pump.
  7. Position the fuel hose clamp (2) at the fuel injection pump.

    8. Object Number: 1872010 Size: SH
  8. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold.
  9. Position the fuel hose clamp (1) at the fuel return pipe.
  10. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
  11. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
  12. Prime the fuel system. Refer to Fuel System Priming.
  13. Start the engine. If the engine stalls, repeat the above step.
  14. Once the engine starts, inspect for fuel leaks.