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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 INJECTOR REPLACEMENT (RIGHT BANK)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation 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.
    Fig 1: View Of Fuel Injectors, Brackets & Injector Locating Pins
    GM660480Courtesy of GENERAL MOTORS COMPANY
  1. If the injector sleeve is pulled from the cylinder head when removing the injector(s), refer to Fuel Injector Nozzle Tube Sleeve Replacement in Engine Mechanical - 6.6L.
  2. Install a NEW O-ring onto the fuel injector(s).
  3. Lubricate the O-ring with clean engine oil.
  4. Install a NEW copper washer into the fuel injector bore in the cylinder head.
  5. Install the fuel injector with injector bracket.
  6. Refer to FASTENER NOTICE in Cautions and Notices.

    Install the injector bracket bolt.

    Tighten 

    Tighten the fuel injector bracket bolt to 50 N.m (37 lb ft).

    7. Fig 2: View Of Fuel Injector Return Pipe
    GM660477Courtesy of GENERAL MOTORS COMPANY
  7. Install the fuel injector return pipe assembly.
  8. Install the fuel injector return line to injector eye bolts and washers. Lubricate the washers with diesel fuel prior to installing.

    Tighten 

    Tighten the fuel injector return line to injector eye bolts to 16 N.m (12 lb ft).

  9. Install the fuel injector return line to cylinder head eye bolts and washers. Lubricate the washers with diesel fuel prior to installing.

    Tighten 

    Tighten the fuel injector return line to cylinder head eye bolts to 17 N.m (12 lb ft).

  10. Install the lower right valve rocker arm cover. Refer to Valve Rocker Arm Lower Cover Replacement - Right Side in Engine Mechanical - 6.6L.
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.