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Home >> Chevrolet >> 2009 >> Chevy Express G2500, Van Cargo Extended, 6.6 6 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 6.6L LMM - Introduction >> Repair Instructions >> Fuel Injector Replacement (Left) >> Removal Procedure

Removal Procedure

  1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (6.6L) .
  2. If equipped, remove the auxiliary generator. Refer to Auxiliary Generator Replacement .
  3. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement .
  4. Remove the injector/glow plug wire harness retaining bolt at lower upper valve cover.
  5. Disconnect the left engine wiring harness connector.
    6. Fig 1: Identifying Engine Wiring Harness Bracket Bolts
    GM1732378Courtesy of GENERAL MOTORS CORP.
  6. Remove the engine wiring harness to bracket bolt, the 2 engine wiring harness bracket to upper valve cover bolts and remove the bracket (1).
    7. Fig 2: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
    NOTE:
    • Prior to removal of the fuel injector pipes, use compressed air to remove any debris from the injector line and fittings.
    • Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist with removal.
  7. Remove the left fuel injector pipes.
    8. Fig 3: Identifying Fuel Return Hose Clip At The Fuel Injector
    GM1732395Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel return hose clips (1).
    9. Fig 4: View Of Fuel Return Hose At The Fuel Injector
    GM1732415Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel return hose from the injectors.
    10. Fig 5: View Of Fuel Injector Engine Wiring Harness Electrical Connector
    GM1732433Courtesy of GENERAL MOTORS CORP.
    CAUTION: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.
  10. Disconnect the fuel injector electrical connectors.
    11. Fig 6: View Of Left Fuel Injector Bracket Bolts
    GM1335618Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel injector bracket bolts.
  12. Fig 7: View Of Left Fuel Injectors W/Brackets
    GM1335621Courtesy of GENERAL MOTORS CORP.

    Install J-46594  into the bolt hole in the fuel injector bracket. See Special Tools .
  13. Install a flare nut wrench onto J-46594  and pull back away from the fuel injector, until the injector releases from its seat. See Special Tools .
  14. Remove J-46594  . See Special Tools .
  15. Remove the fuel injectors with brackets.
  16. Remove and discard the copper washer from the fuel injector bore.
  17. Remove and discard the fuel injector O-ring from the injector.
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