GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Injection Pump Replacement

Removal Procedure

    Object Number: 1866922 Size: SH
  1. Drain the cooling system. Refer to Cooling System Draining and Filling.
  2. Remove the fan. Refer to Fan Replacement.
  3. Remove the fuel return pipe to fuel injection pump fuel hose. Refer to Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump.
  4. Remove the fuel injection pump to fuel feed block fuel hose. Refer to Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block.
  5. Remove the right side fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side.
  6. Remove the left side fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side.
  7. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
  8. Remove the center intake manifold. Refer to Center Intake Manifold Replacement
  9. Remove the fuel injection pump bolts (1).

    10. Object Number: 1866923 Size: SH

    Note: Be careful not to damage any mating surfaces.

  10. Remove the fuel injection pump (1) from the block. Use 2 screwdrivers to work the pump from the block towards the rear of engine keeping the pump straight.
  11. The fuel injection pump may need to be rotated in order to remove it from the vehicle.

Fuel Injection Pump Preparation Procedure
  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.

    7. Caution: Refer to Fastener Caution in the Preface section.

  7. Install the adapter on the pump.
  8. Install the 3 bolts and spacers.

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

  9. Install the gear and nut.

    10. Tighten
    Tighten nut to 70 N·m (52 lb ft).

Installation Procedure

    Object Number: 1866923 Size: SH
  1. Install the fuel injection pump (1) to the block.

    2. Object Number: 1866922 Size: SH
  2. Install the fuel injection pump bolts (1).

    3. Tighten
    Tighten bolts to 21 N·m (15 lb ft).

  3. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement.
  4. Install the left side fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side.
  5. Install the right side fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side.
  6. Install the fuel injection pump to fuel feed block fuel hose. Refer to Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block.
  7. Install the fuel return pipe to fuel injection pump fuel hose. Refer to Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump.
  8. Install the fan. Refer to Fan Replacement.
  9. Fill the cooling system. Refer to Cooling System Draining and Filling.
  10. Prime the fuel system. Refer to Fuel System Priming.
  11. Start the engine. If the engine stalls, repeat the above step.
  12. Once the engine starts, inspect for fuel leaks.