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Home >> Chevrolet >> 2011 >> Chevy Express G2500, Van Cargo Extended, 6.6 L >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 6.6L (LGH) - Repair Instructions >> Repair Instructions >> Fuel Injector Replacement (Left Side) >> Removal Procedure

Removal Procedure

  1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (4.3L, 4.8L, 5.3L, 6.0L, 6.2L, 7.0L) , Engine Coolant Fan Upper Shroud Replacement (Diesel) .
  2. If equipped, remove the auxiliary generator. Refer to Auxiliary Generator Replacement (KD9) .
  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: Engine Wiring Harness Bracket Fasteners
    GM2369489Courtesy of GENERAL MOTORS CORP.
  6. Remove the engine wiring harness bracket fasteners (1) and reposition the wiring harness.
    7. Fig 2: Fuel Injector Electrical Connectors
    GM2369508Courtesy 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.

  7. Disconnect the fuel injector electrical connectors (1).
    8. Fig 3: Fuel Return Pipes
    GM2369711Courtesy of GENERAL MOTORS CORP.
  8. Disconnect and reposition the fuel return pipes (1).
    9. Fig 4: Fuel Injector Pipes
    GM2369757Courtesy 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.
  9. Remove the fuel pipe bracket fasteners (1) and fuel injector pipes (2).
    10. Fig 5: Fuel Injector Bracket Bolts
    GM2369529Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel injector bracket bolts (1).
  11. Fig 6: Fuel Injectors (Left Side Shown, Right Side Similar)
    GM2369542Courtesy of GENERAL MOTORS CORP.

    Install EN-49774  puller into the bolt hole in the fuel injector bracket.
  12. Install a flare nut wrench onto EN 49774  puller, and work the tool outward until the injector releases from its seat.
  13. Remove the EN-49774  puller.
  14. Remove the fuel injectors (1) with brackets (2).
  15. Remove and discard the copper washer from the fuel injector bore.
  16. Remove and discard the fuel injector O-ring from the injector.
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