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Home >> Pontiac >> 2001 >> Aztek Base, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 944 (Engine Controls - 6.6L (LLY) (Introduction)) >> Repair Instructions >> Fuel Injector Replacement (Left) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Fuel Injector Copper Washers
    GM1335628Courtesy of GENERAL MOTORS CORP.
  1. If necessary, install a NEW O-ring onto the fuel injector.
  2. If necessary, install a NEW copper washer to the fuel injector bore.
  3. If necessary, install the fuel injector bracket pins.
    4. Fig 2: View Of Left Fuel Injectors W/Brackets
    GM1335621Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel injectors with brackets.
    5. Fig 3: View Of Left Fuel Injector Bracket Bolts
    GM1335618Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the fuel injector bracket bolts.

    Tighten:  Tighten the bolts to 30 N.m (22 lb ft).

    6. Fig 4: View Of Fuel Injector Electrical Connectors
    GM1335536Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel injector electrical connectors.
    7. Fig 5: View Of Fuel Return Hose & Injectors
    GM1335588Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel return hose to the injectors.
  8. Install the fuel return hose clips.
    9. Fig 6: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.
  9. Install the fuel injector pipes.

    Tighten:  Tighten the fittings to 41 N.m (30 lb ft).

  10. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
  11. Install the PCV hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .
    12. Fig 7: Glow Plug Controller Battery Feed Electrical Connector
    GM1409333Courtesy of GENERAL MOTORS CORP.
  12. Connect the glow plug controller battery feed electrical connector (1).
    13. Fig 8: View Of Glow Plug Controller Electrical Connectors
    GM1335531Courtesy of GENERAL MOTORS CORP.
  13. Connect the glow plug controller electrical connector.
    14. Fig 9: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  14. Install the main electrical harness bracket.
  15. Install the main electrical harness bracket bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

  16. Connect the barometric sensor electrical connector.
  17. Install the engine wire harness to the clip.
    18. Fig 10: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  18. Install the main electrical connectors to the bracket.
  19. Install the engine harness main electrical connectors bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

    20. Fig 11: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  20. Connect the main engine electrical harness connectors.
  21. Push down on the latches (1) in order to connect the connectors.
  22. Close the harness clip (2).
    23. Fig 12: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  23. Remove the tape from the turbocharger openings.
  24. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  25. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

  26. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  27. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  28. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  29. Prime the fuel system. Refer to Fuel System Priming .
  30. Start the engine. If the engine stalls, repeat the above step.
  31. Once the engine starts, inspect for fuel leaks.
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