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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 676 (ENGINE CONTROLS - 6.6L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL INJECTION PUMP REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2006 GMC Sierra, 2006 GMC Cab & Chassis Sierra, 2006 Chevrolet Silverado, and 2006 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Remove the wiring harness retainer from the bracket.
  5. Remove the oil level indicator tube bolt.
  6. Remove the oil level indicator tube bracket bolts.
    Fig 1: Removing Tube Bracket Bolts
    GM1601448Courtesy of GENERAL MOTORS CORP.
  7. Remove the bracket.
  8. Drain the cooling system. Refer to Draining and Filling Cooling System (w/RPO HP2) or Draining and Filling Cooling System (w/o RPO HP2) .
  9. Remove the fan. Refer to Fan Replacement (Diesel) or Fan Replacement (Gasoline) .
  10. Remove the battery cable junction block bolt (1) from the power steering pump bracket.
    Fig 2: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  11. Reposition the battery cables out of the way.
    12. Fig 3: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  13. Disconnect the A/C cut out switch electrical connector.
  14. Remove the A/C compressor bolts.
  15. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.
    16. Fig 4: Removing Rear Power Steering Pump Bracket & Bolts
    GM656330Courtesy of GENERAL MOTORS CORP.
  16. Remove the power steering pump bracket rear bolts (1).
  17. Reposition the power steering pump, with the hoses attached, to the right side of the engine compartment.
  18. Remove the A/C compressor/power steering pump bracket bolts and bracket.
    Fig 5: Removing A/C Compressor/Power Steering Pump Bracket
    GM1602063Courtesy of GENERAL MOTORS CORP.
  19. Remove the heater outlet hose bolt from the generator bracket.
    20. Fig 6: View Of Drive Belt Tensioner
    GM1334909Courtesy of GENERAL MOTORS CORP.
  20. Remove the drive belt tensioner and bolt.
  21. Remove the generator. Refer to Generator Replacement (4.8L, 5.3L, and 6.0L Engines) or Generator Replacement (6.6L (LLY) Engine) or Generator Replacement (8.1L Engine) .
  22. Remove the generator bracket bolts and bracket.
    Fig 7: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  23. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (6.6L (LLY) Engine) .
  24. Disconnect the fuel balance pipe fitting from the right fuel rail.
    Fig 8: View Of Fuel Rail Balance Pipe & Bolts
    GM1335586Courtesy of GENERAL MOTORS CORP.
  25. Remove the fuel balance pipe retainer bolts.
    26. Fig 9: View Of Left Fuel Rail At Pump Pipe
    GM1335603Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the fuel rail inlet pipe from the injection pump and rail.
  27. Remove the inlet pipe.
  28. Remove the center intake manifold. Refer to Intake Manifold Replacement - Center .
    29. Fig 10: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  29. Reposition the injection pump hose clamps at the fuel line.
  30. Remove the hoses from fuel lines.
  31. Remove the fuel injection pump bolts.
    IMPORTANT: Be careful not to damage any mating surfaces.
  32. Remove the fuel injection pump from the block.
    Fig 11: Removing Fuel Injection Pump & Bolts
    GM1336114Courtesy of GENERAL MOTORS CORP.

    Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight.

  33. The fuel injection pump may need to be rotated in order to remove it from the vehicle.
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.