Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISENGINE PERFORMANCEREMOVE, OVERHAUL & INSTALLENGINE CONTROLS - REMOVAL, OVERHAUL & INSTALLATIONFUEL SYSTEMS (DIESEL)INJECTION PUMPREMOVAL (6.6L)
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8
Removal (6.6L)
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Removal (6.6L)
NOTE:
Cap all open fuel connections with plastic plugs in order to prevent contamination of fuel system.
- Disconnect negative battery cables. Remove air intake duct. Drain cooling system. Remove upper fan shroud and fan blade assembly. Remove serpentine belt. Remove bolt holding positive battery cable junction box and bracket and set aside.
- Remove A/C compressor and power steering pump and bracket and set aside without disconnecting lines. Remove oil filler tube. Remove alternator and bracket. Remove thermostat housing bracket and wiring. Remove Positive Crankcase Ventilation (PCV) catch tank and move aside. Remove turbo cooling hose return line and hose. Remove all wiring connectors and place harness out of way. Remove air intake pipe. Remove water crossover assembly. Remove hose to turbo water feed line.
- Disconnect all high pressure fuel lines and remove supply pipe and hose at fuel injection pump and junction block. Remove return fuel hose from injection pump. Disconnect "Y" junction banjo fitting at junction block. Remove bolts holding fuel injection pump, 2 bolts in front cover and 2 bolts in block. Remove fuel injection pump from block using 2 screwdrivers to work pump from block toward rear of engine. SeeFigure
- To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.