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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 939 (ENGINE CONTROLS - 6.6L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL INJECTION PUMP REPLACEMENTFUEL INJECTION PUMP INSTALLATION
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Fuel Injection Pump Installation

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Fuel Injection Pump Installation
WARNING: This page is about a different car, the 2001 GMC Sierra, 2001 GMC Cab & Chassis Sierra, 2001 Chevrolet Silverado, and 2001 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Fuel Injection Pump & Bolts
    GM660523Courtesy of GENERAL MOTORS COMPANY
  1. Install the fuel injection pump.
  2. Refer to FASTENER NOTICE in Cautions and Notices.

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

    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.

    Tighten 

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

    4. Fig 2: View Of Fuel Return Hose & Fuel Injection Pump High Pressure Line From Fuel Injection Pump
    GM660448Courtesy of GENERAL MOTORS COMPANY
  4. Install the fuel supply hose and hose clamp to the fuel injection pump.
  5. Install fuel return hose and hose clamp to the fuel injection pump.
  6. Install the high pressure lines from the injection pump to the junction block.

    Tighten 

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

  7. Install the fuel pressure sensor connector at the junction block.
  8. Replace hose to turbo water feed line. Refer to Turbocharger Coolant Hoses/Pipes Replacement in Engine Cooling.
  9. Install water crossover assembly. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
  10. Install air intake pipe. Refer to Air Intake Pipe Replacement .
    11. Fig 3: Heater Pipe & Bolt
    GM660425Courtesy of GENERAL MOTORS COMPANY
  11. Install the heater pipe using the following procedure:
    1. Install new O-ring lubricated with clean engine oil.
    2. Install the heater pipe bracket bolt.

      Tighten 

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

    3. Install the heater pipe to water crossover bolts.

      Tighten 

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

    12. Fig 4: Engine Wiring Harness
    GM660421Courtesy of GENERAL MOTORS COMPANY
  12. Connect the engine wiring harness.
  13. Install upper radiator hose at outlet pipe using the following procedure:
    • Install upper radiator hose mounting bolts and brackets.

      Tighten 

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

    • Install the upper radiator hose clamp.
  14. Install turbo cooling hose return and clamp.
    15. Fig 5: Thermostat Housing Bracket
    GM660352Courtesy of GENERAL MOTORS COMPANY
  15. Install the left idler pulley and bolt.
  16. Install PCV catch tank, hose clamp and bolt to the right front of the engine.
  17. Install the thermostat housing bracket, wiring, fuel test port and nuts.
  18. Install the alternator. Refer to Generator Replacement (6.6 L Engine) in Engine Electrical.
  19. Install a new O-ring to the oil fill tube and lubricate the O-ring with clean engine oil.
  20. Install the oil fill tube. Refer to Oil Filler Tube Replacement in Engine Mechanical.
    21. Fig 6: View Of A/C Compressor & Power Steering Pump Bracket & Bolts
    GM660344Courtesy of GENERAL MOTORS COMPANY
  21. Install air conditioning/power steering bracket and bolts.

    Tighten 

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

  22. Install the power steering pump. Refer to Power Steering Pump Replacement (6.6L Diesel) in Power Steering System.
  23. Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement (LB7 w/ Harrison) , Air Conditioning Compressor Replacement (LB7 w/ Denso) in HVAC.
  24. Install the positive battery cable junction box and bolt.
  25. Install the serpentine belt. Refer to Drive Belt Replacement in Engine Mechanical.
  26. Install the fan blade assembly. Refer to Fan Replacement in Engine Cooling.
  27. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement in Engine Cooling.
  28. Refill the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  29. Install the air intake duct between the air cleaner and the turbocharger inlet housing.
  30. Reconnect 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.
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.