LLY 04.5 Fuel Injection Pump Replacement - Diesel Truck Forum - TheDieselGarage.com
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LLY 04.5 Fuel Injection Pump Replacement

Service Information


Document ID: 1380440

Fuel Injection Pump Replacement
Removal Procedure





  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  2. Disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Remove the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  5. Drain the cooling system. Refer to Cooling System Draining and Filling .
  6. Remove the fan. Refer to Fan Replacement in Engine Cooling.
  7. Remove the battery cable junction block bolt (1) from the power steering pump bracket.
  8. Reposition the battery cables out of the way.



  9. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  10. Disconnect the A/C cut out switch electrical connector.
  11. Remove the A/C compressor bolts.
  12. Reposition the A/C compressor, with the hoses attached, to the right side of the engine compartment.



  13. Remove the power steering pump bracket rear bolts (1).
  14. Reposition the power steering pump, with the hoses attached, to the right side of the engine compartment.



  15. Remove the A/C compressor/power steering pump bracket bolts and bracket.
  16. Remove the heater outlet hose bolt from the generator bracket.



  17. Remove the drive belt tensioner and bolt.



  18. Remove the generator. Refer to Generator Replacement in Engine Electrical.
  19. Remove the generator bracket bolts and bracket.
  20. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.



  21. Disconnect the fuel balance pipe fitting from the right fuel rail.
  22. Remove the fuel balance pipe retainer bolts.



  23. Disconnect the fuel rail inlet pipe from the injection pump and rail.
  24. Remove the inlet pipe.
  25. Remove the center intake manifold. Refer to Center Intake Manifold Replacement in Engine Mechanical - 6.6L (LLY).



  26. Reposition the injection pump hose clamps at the fuel line.
  27. Remove the hoses from fuel lines.



  28. Remove the fuel injection pump bolts. Important: Be careful not to damage any mating surfaces.

  29. 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.
  30. 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 Nm (15 lb ft).
  9. Install the gear and nut. Tighten
    Tighten nut to 70 Nm (52 lb ft).
Installation Procedure






  1. Install the fuel injection pump to the block.
  2. Install the fuel injection pump bolts. Tighten
    Tighten the bolts to 21 Nm (15 lb ft).




  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 in Engine Mechanical - 6.6L (LLY).



  6. Install the inlet pipe.
  7. Connect the fuel rail inlet pipe to the injection pump and rail. Tighten
    Tighten the fittings to 41 Nm (30 lb ft).




  8. Connect the fuel balance pipe fitting to the right fuel rail. Tighten
    Tighten the fitting to 41 Nm (30 lb ft).

  9. Install the fuel balance pipe retainer bolts. Tighten
    Tighten the bolts to 10 Nm (89 lb in).

  10. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement in Engine Cooling.



  11. Install the generator bracket and bolts. Tighten
    Tighten the bolts to 46 Nm (34 lb ft).

  12. Install the generator. Refer to Generator Replacement in Engine Electrical.



  13. Install the drive belt tensioner and bolt. Tighten
    Tighten the bolt to 50 Nm (37 lb ft).

  14. Install the heater outlet hose bolt to the generator bracket Tighten
    Tighten the bolt to 21 Nm (15 lb ft).

  15. Install the oil level indicator tube bracket bolt. Tighten
    Tighten the bolt to 21 Nm (15 lb ft).




  16. Install the A/C compressor/power steering pump bracket and bolts. Tighten
    Tighten the bolt to 46 Nm (34 lb ft).




  17. Position the power steering pump, with the hoses attached, to the bracket.
  18. Install the power steering pump bracket rear bolts (1). Tighten
    Tighten the bolts to 50 Nm (37 lb ft).




  19. Position the A/C compressor, with the hoses attached, to the bracket.
  20. Install the A/C compressor bolts. Tighten
    Tighten the bolts to 50 Nm (37 lb ft).

  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 Nm (80 lb in).

  25. Install the fan. Refer to Fan Replacement in Engine Cooling.
  26. Install the fuel injection control module. Refer to Fuel Injector Control Module Replacement .
  27. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  28. Install the air cleaner outlet duct. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
  29. Connect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  30. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  31. Prime the fuel system. Refer to Fuel System Priming .
  32. Start the engine. If the engine stalls, repeat the above step.
  33. Once the engine starts, inspect for fuel leaks.
2008 General Motors Corporation. All rights reserved.


Devil Girl 2006 2500HD LBZ Ex-Cab 4x4

EFI Live tuned by IdahoRob,MPI twins installed by BigDipper,PPE lift pump, BigDipper 30% injectors, BigDipper Trans Precion ML converter.PPE Twin Cp3's.

Alot Of thanks To Kat & Pat at duramax diesels, Joe & Dan at PPE,George aka BigDipper
RIP LBZ 6/1/[email protected]:44pm she was strong

She's Alive again

Born on July 27, 2008, 11:59:02 PM

http://www.dieselbuilder.com/Media/P...adoBuild_2.pdf
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