fuel injection pump replacement - dieselplace.com

2006 GMC Truck GMC K Sierra - 4WD | Sierra, Silverado (VIN C/K) Service Manual | Document ID: 1602254

Fuel Injection Pump Replacement

Removal Procedure

1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .

2. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and

Connection .

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.

7. Remove the bracket.

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8. Drain the cooling system. Refer to Cooling System Draining and Filling .

9. Remove the fan. Refer to Fan Replacement .

10. Remove the battery cable junction block bolt (1) from the power steering pump bracket.

11. Reposition the battery cables out of the way.

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. 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.

19. Remove the heater outlet hose bolt from the generator bracket.

20. Remove the drive belt tensioner and bolt.



21. Remove the generator. Refer to Generator Replacement .

22. Remove the generator bracket bolts and bracket.

23. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover

Replacement .

24. Disconnect the fuel balance pipe fitting from the right fuel rail.

25. Remove the fuel balance pipe retainer bolts.



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 Center Intake Manifold Replacement .

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.

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.

Preparing The Fuel Injection Pump

1. Hold the fuel pump by the drive gear in a vice with copper jaw liners.

2. Loosen the gear nut until the nut is even with the end of the gear shaft.

3. Remove the gear from the tapered shaft of the injection pump.

4. Separate the injection pump and adapter by removing the 3 bolts and spacers.

5. Inspect the O-ring for damage on the pump adapter and replace, if necessary. Lubricate the

O-ring with clean engine oil.

6. Clean all mating surfaces.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the adapter on the pump.

8. Install the 3 bolts and spacers.

Tighten

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

9. Install the gear and nut.

Tighten



Tighten nut to 70 N�m (52 lb ft).

Installation Procedure

1. Install the fuel injection pump to the block.

2. Install the fuel injection pump bolts.

Tighten


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 Center Intake Manifold Replacement .

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. Connect the fuel balance pipe fitting to the right fuel rail.

Tighten

Tighten the fitting to 41 N�m (30 lb ft).



9. Install the fuel balance pipe retainer bolts.

Tighten

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

10. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover

Replacement .

11. Install the generator bracket and bolts.

Tighten


12. Install the generator. Refer to Generator Replacement .



13. Install the drive belt tensioner and bolt.

Tighten

Tighten the bolt to 50 N�m (37 lb ft).

14. Install the heater outlet hose bolt to the generator bracket

Tighten


15. Install the oil level indicator tube bracket bolt.

Tighten


16. Install the A/C compressor/power steering pump bracket and bolts.

Tighten




17. Position the power steering pump, with the hoses attached, to the bracket.

18. Install the power steering pump bracket rear bolts (1).

Tighten


19. Position the A/C compressor, with the hoses attached, to the bracket.

20. Install the A/C compressor bolts.

Tighten




21. Connect the A/C cut out switch electrical connector.

22. Connect the A/C compressor clutch electrical connector.

23. Position the battery cables to the bracket.

24. Install the battery cable junction block bolt to the power steering pump bracket.

Tighten

Tighten the bolts to 9 N�m (80 lb in).

25. Install the fan. Refer to Fan Replacement .

26. Install the bracket.

27. Install the oil level indicator tube bracket bolts.

Tighten




28. Install the oil level indicator tube bolt.

Tighten


29. Install the wiring harness retainer to the bracket.

30. Fill the cooling system. Refer to Cooling System Draining and Filling .

31. Install the air cleaner outlet duct. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube

Replacement .

32. Connect negative battery cable. Refer to Battery Negative Cable Disconnection and

Connection .

33. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .

34. Prime the fuel system. Refer to Fuel System Priming .

35. Start the engine. If the engine stalls, repeat the above step.

36. Once the engine starts, inspect for fuel leaks.



fuel injection pump replacement - dieselplace.com

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