GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2004 🢒 TopKick C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Controls - 6.6L (LB7) 🢒 Fuel Injection Pump Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect negative battery cables from both batteries.
  2. Remove the air cleaner layer. Refer to Air Cleaner Replacement .
  3. Remove the air intake duct between the air cleaner and the turbocharger inlet housing.

    4. Important: Cover the air intake pipe end with duct tape to prevent the infiltration of dirt.

  4. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Remove the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  6. Remove the fan blade assembly. Refer to Fan Replacement in Engine Cooling.
  7. Remove the serpentine belt.
  8. Remove the bolt holding positive battery cable junction box and bracket and move out of the way.

    9. Important: Remove only the air conditioning/power steering bracket. Do not discharge the A/C or remove the A/C and power steering lines.

  9. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
  10. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  11. Position the A/C compressor and power steering pump aside.
  12. Remove the oil filler tube. Refer to Oil Filler Tube Replacement in Engine Mechanical-6.6L.
  13. Remove the air conditioning/power steering bracket.
  14. Remove the alternator. Refer to Generator Replacement in Engine Electrical.
  15. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts.
  16. Remove the positive crankcase ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and move to the side.
  17. Remove the alternator bracket. Refer to Generator Bracket Replacement in Engine Electrical.
  18. Remove the turbo cooling hose return line clamp and hose.
  19. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way.
  20. Remove bolt holding wiring support bracket at thermostat housing.
  21. Move the main wiring harness by disconnecting the following:
    22. • The fuel pressure regulator connector on the fuel injection pump
    • The fuel injection control module connectors
  22. Flip the wire harness and harness tray towards the back and set aside.
  23. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing.
  24. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .
  25. Remove the water crossover assembly. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
  26. Remove the hose to the turbo water feed line. Refer to Turbocharger Coolant Hoses/Pipes Replacement in Engine Cooling.

    27. Important: Cap all of the open fuel connections with suitable plastic plugs in order to prevent infiltration of dirt.

  27. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and function block. Refer to Metal Collar Quick Connect Fitting Service .

    28. Object Number: 660448 Size: SH
  28. Remove the return fuel hose from fuel injection pump.
  29. Disconnect the y-junction banjo fitting at the junction block.
  30. Remove the bolts holding the fuel injection pump, two bolts in front cover and two bolts in the block.

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

  31. Remove fuel injection pump from the block using two screwdrivers to work the pump from the block towards rear of engine keeping the pump straight.

    32. Object Number: 660523 Size: SH
  32. Remove fuel injection pump.

Preparing Fuel 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 pump.
  4. Separate the pump and adapter by removing the three bolts and spacers.
  5. Inspect the O-ring for damage on pump adapter and replace, if necessary. Lubricate the O-ring with clean engine oil.
  6. Clean all mating surfaces.
  7. Install the adapter on the pump.

    8. 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.

  8. Using the three bolts and spacers, assemble the pump.

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

  9. Replace the gear and nut.

    10. Tighten
    Tighten the nut to 70 N·m (52 lb ft).

Installation Procedure

    Object Number: 660523 Size: SH
  1. Install the fuel injection pump.

    2. 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.

  2. Install the fuel injection pump mounting bolts from the front of the engine front cover.

    3. Tighten
    Tighten the fuel injection pump mounting bolts to 20 N·m (15 lb ft).

  3. Reconnect the fuel return line banjo bolt at the junction block.

    4. Tighten
    Tighten the banjo bolt to 15 N·m (11 lb ft).

  4. Install fuel return hose and hose clamp to the fuel injection pump.
  5. Install high pressure lines from injection pump to junction block.

    6. Tighten
    Tighten the high pressure lines to 44 N·m (32 lb ft).

  6. Install the fuel pressure sensor connector at the junction block.
  7. Replace hose to turbo water feed line. Refer to Turbocharger Coolant Hoses/Pipes Replacement in Engine Cooling.
  8. Install water crossover assembly. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
  9. Install air intake pipe. Refer to Air Intake Pipe Replacement .

    10. Object Number: 660425 Size: SH
  10. Install the heater pipe using the following procedure:
    11. 10.1. Install new O-ring lubricated with clean engine oil.
    10.2. Install the heater pipe bracket bolt.

    Tighten
    Tighten the bracket bolt to 20 N·m (15 lb ft).

    10.3. Install the heater pipe to water crossover bolts.

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


    Object Number: 660421 Size: SH
  11. Connect the engine wiring harness.
  12. Install upper radiator hose at outlet pipe using the following procedure:
    13. 12.1. Install upper radiator hose mounting bolts and brackets.

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

    12.2. Install the upper radiator hose clamp.
  13. Install turbo cooling hose return and clamp.

    14. Object Number: 660352 Size: SH
  14. Install the left idler pulley and bolt.
  15. Install PCV catch tank, hose clamp and bolt to the right front of the engine.
  16. Install the thermostat housing bracket, wiring, fuel test port and nuts.
  17. Install the alternator. Refer to Generator Replacement in Engine Electrical.
  18. Install a new O-ring to the oil fill tube and lubricate the O-ring with clean engine oil.
  19. Install the oil fill tube. Refer to Oil Filler Tube Replacement in Engine Mechanical-6.6L.

    20. Object Number: 660344 Size: SH
  20. Install air conditioning/power steering bracket and bolts.

    21. Tighten
    Tighten the air conditioning and power steering bracket bolts to 46 N·m (34 lb ft).

  21. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
  22. Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement in Heating, Ventilation and Air Conditioning.
  23. Install the positive battery cable junction box and bolt.
  24. Install the serpentine belt. Refer to Drive Belt Replacement in Engine Mechanical-6.6L.
  25. Install the fan blade assembly. Refer to Fan Replacement in Engine Cooling.
  26. Install the upper fan shroud. Refer to Fan Shroud Replacement in Engine Cooling.
  27. Refill the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  28. Install the air intake duct between the air cleaner and the turbocharger inlet housing.
  29. Install the air cleaner layer. Refer to Air Cleaner Replacement .
  30. Connect the negative battery cables to both batteries.
  31. Replace all of the hold down ties.
  32. Start the engine and check for leaks or noises.
  33. After the engine warms up, refill coolant reservoir to proper level.