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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 REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Removal Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Removal Procedure
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.
    CAUTION:

    Refer to BATTERY DISCONNECT CAUTION in Cautions and Notices.

  1. Disconnect negative battery cables from both batteries.
  2. Remove the air intake duct between the air cleaner and the turbocharger inlet housing.
    3. IMPORTANT:

    Cover the air intake pipe end with duct tape to prevent the infiltration of dirt.

  3. Drain the coolant. Refer to Cooling System Draining and Filling .
  4. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement in Engine Cooling.
  5. Remove the fan blade assembly. Refer to Fan Replacement in Engine Cooling.
  6. Remove the serpentine belt.
  7. Remove the bolt holding positive battery cable junction box and bracket and move out of the way.
    8. IMPORTANT:

    Remove only the air conditioning/power steering bracket. Do not discharge the A/C or remove the A/C and power steering lines.

  8. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LB7 w/ Harrison) , Air Conditioning Compressor Replacement (LB7 w/ Denso) in HVAC.
  9. Remove the power steering pump. Refer to Power Steering Pump Replacement (6.6L Diesel) in Power Steering Systems.
  10. Position the A/C compressor and power steering pump aside.
  11. Remove the oil filler tube. Refer to Oil Filler Tube Replacement in Engine Mechanical.
  12. Remove the air conditioning/power steering bracket.
  13. Remove the alternator. Refer to Generator Replacement (6.6 L Engine) in Engine Mechanical.
  14. Remove the thermostat housing bracket, wiring and fuel test port, and two nuts.
  15. Remove the positive crankcase ventilation (PCV) catch tank from the PCV bracket and bolt below holding lower line, and move to the side.
  16. Remove the alternator bracket.
  17. Remove the turbo cooling hose return line clamp and hose.
  18. Remove the upper radiator hose at the outlet pipe. Remove the bracket and support the bracket at the valve cover, and swing out of the way.
  19. Remove bolt holding wiring support bracket at thermostat housing.
  20. Move the main wiring harness by disconnecting the following:
    • The fuel pressure regulator connector on the fuel injection pump
    • The fuel injection control module connectors
  21. Flip the wire harness and harness tray towards the back and set aside.
  22. Disconnect the heater pipe bolt and temperature sensor wire from the thermostat housing.
  23. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .
  24. Remove the water crossover assembly. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.
  25. Remove the hose to the turbo water feed line. Refer to Turbocharger Coolant Hoses/Pipes Replacement in Engine Cooling.
    26. IMPORTANT:

    Cap all of the open fuel connections with suitable plastic plugs in order to prevent infiltration of dirt.

  26. Disconnect all high pressure fuel lines and remove supply pipe and hose at the fuel injection pump and function block. Refer to Metal Collar Quick Connect Fitting Service .
    27. Fig 1: View Of Fuel Return Hose & Fuel Injection Pump High Pressure Line From Fuel Injection Pump
    GM660448Courtesy of GENERAL MOTORS COMPANY
  27. Remove the supply hose from the fuel injection pump.
  28. Remove the fuel return hose from the fuel injection pump.
  29. Remove the high pressure line from the injection pump to the junction block.
    30. IMPORTANT:

    Be careful not to damage any mating surfaces.

  30. Remove fuel injection pump from the block using two screwdrivers to work the pump from the block towards rear of engine keeping the pump straight.
    31. Fig 2: View Fuel Injection Pump & Bolts
    GM660523Courtesy of GENERAL MOTORS COMPANY
  31. Remove fuel injection pump.
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.