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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROL SYSTEM - 6.6L (LLY) - INTRODUCTION (2 OF 2)REPAIR INSTRUCTIONSFUEL INJECTION PUMP REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
    Fig 1: View Of Fuel Injection Pump
    GM1336114Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel injection pump to the block.
  2. Install the fuel injection pump bolts.

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

    3. Fig 2: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  3. Install the hoses to fuel lines.
  4. Position the injection pump hose clamps at the fuel line.
  5. Install the center intake manifold. Refer to Intake Manifold Replacement - Center .
    6. Fig 3: View Of Left Fuel Rail At Pump Pipe
    GM1335603Courtesy of GENERAL MOTORS CORP.
  6. Install the inlet pipe.
  7. Connect the fuel rail inlet pipe to the injection pump and rail.

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

    8. Fig 4: View Of Fuel Rail Balance Pipe & Bolts
    GM1335586Courtesy of GENERAL MOTORS CORP.
  8. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
    9. Fig 5: Wiring Harness Retainer
    GM1601448Courtesy of GENERAL MOTORS CORP.
  9. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac N Fill) .
  10. Install the air cleaner outlet duct. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  11. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  12. Prime the fuel system. Refer to Fuel System Priming .
  13. Start the engine. If the engine stalls, repeat the above step.
  14. Once the engine starts, inspect for fuel leaks.
  15. Install the engine cover. Refer to Engine Cover Replacement .
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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.