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2002 Chevrolet Silverado 6.6L Eng 2500 HD
INJECTORS FUEL
REQUESTED INFORMATION
FUEL INJECTOR
Tip: Injector Sleeve
Question: Injector Hold Down Torque?
Removal
Remove the lower valve rocker arm cover. Remove the return line from injectors. Remove the retaining bolt
from the injector bracket. Install the Fuel Injector Puller (J 44639) on the injector retainer bracket. Confirm
which side of the banjo washers have the largest hole. Install a wrench on the J 44639 and pry away from the
fuel injector. Remove the faulty injectors. See Fig 1. Remove the copper compression washer from injection
hole if the washer did not remove with the injector.
Installation
NOTE: Always install new copper gaskets on the
fuel injector lines.
1. If the injector sleeve was pulled from the cylinder head when removing the injector(s), continue with
this step. If the injector sleeve was not pulled from cylinder head, go to step 3. Clean the fuel
injector sleeve bore with GM P/N 12377981 or equivalent. Lubricate and install NEW "O" rings onto
the fuel injector sleeve.
2. Install the fuel injector sleeve onto the Fuel Injector Sleeve Remover/Installer (J 45910). Apply GM
P/N United States 12345493 or equivalent to the fuel injector sleeve lower sealing area. Install the
fuel injector sleeve with J 45910 into the cylinder head. Lightly tap on the J 45910 with a hammer to
install and seat the fuel injector sleeve. Remove the J 45910 from the fuel injector sleeve.
3. Install the NEW injectors. Install the retaining bolt on the injector bracket. Install the injector bracket
bolt. Tighten the fuel injector bracket bolt to 50 N.m (37 lb ft). Install the return line fuel injector.
Install the lower left valve rocker arm cover.
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Fig 1: Removing Fuel Injector
Courtesy of GENERAL MOTORS CORP.
Fuel Injector Sleeve Removal
Tools Required
J 45910 Fuel Injector Sleeve Remover/Installer
1. Install J 45910 into the fuel injector sleeve.
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Fig 2: Fuel Injector Sleeve Remover/Installer
Courtesy of GENERAL MOTORS CORP.
2. Tighten the nut while holding J 45910 .
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Fig 3: Tightening Nut While Holding Fuel Injector Sleeve Remover/Installer
Courtesy of GENERAL MOTORS CORP.
3. Install J 45910-2 over J 45910-1 which are both part of kit J 45910 , and add the washer and nut.
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Fig 4: Installing J 45910-2 Over J 45910-1 & Adding Washer & Nut
Courtesy of GENERAL MOTORS CORP.
4. Hold J 45910 while turning the nut to remove the fuel injector sleeve.
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Fig 5: Removing Fuel Injector Sleeve
Courtesy of GENERAL MOTORS CORP.
5. Remove J 45910 with the fuel injector sleeve.
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Fig 6: Removing J 45910 With Fuel Injector Sleeve
Courtesy of GENERAL MOTORS CORP.
6. Remove the O-rings (1).
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Fig 7: Removing O-Rings
Courtesy of GENERAL MOTORS CORP.
FUEL INJECTORS
NOTE: Fuel injectors are not interchangeable.
Each fuel injector is calibrated for a specific flow rate.
Installation
1. Lubricate "O" ring seals on NEW fuel injector with clean engine oil. Install fuel injector into fuel meter
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body assembly. Install injector assembly retainer. Install injector retainer lock nuts and tighten to
specification. See TORQUE SPECIFICATIONS .
2. To complete installation, reverse removal procedure. Turn ignition switch to ON position for 2
seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to ON position.
Check for fuel leaks. Repair as necessary.
Installation
1. To install, reverse removal procedure. Coat NEW crossover pipe and injector "O" rings with clean
engine oil. Install injector(s) into fuel rail. Install injector retainer(s). Ensure injector(s) rotate
smoothly and freely. If "O" rings are installed incorrectly, injectors will bind.
2. Apply a small amount of Threadlock (12345382) to threads on fuel rail retaining bolts. Tighten
fasteners to specification. See TORQUE SPECIFICATIONS . Rotate injectors as necessary in order
to avoid stretching of injector harness.
3. To complete installation, reverse removal procedure. Turn ignition switch to ON position for 2
seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to ON position.
Check for fuel leaks. Repair as necessary.
NOTE: When ordering new fuel injectors, ensure
to order the correct injector(s) for the application being
serviced.
Installation
1. Lubricate "O" ring seals on NEW fuel injector(s) with clean engine oil. Install fuel injector(s) into fuel
rail with injector electrical connector facing outwards. Install fuel injector retainer(s).
2. Apply a small amount of Threadlock (12345382) to threads on fuel rail mounting bolts. Install fuel
rail. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Rotate injectors as
necessary in order to avoid stretching of injector harness.
3. To complete installation, reverse removal procedure. Turn ignition switch to ON position for 2
seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to ON position.
Check for fuel leaks. Repair as necessary.
Fuel Injectors Removal
Tools Required
J 44639 Injector Removal Tool
1. Remove the fuel injector return pipe eye bolts and gaskets.
2. Remove the fuel injector return pipe assembly.
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Fig 8: Fuel Injector Return Pipe Assembly
Courtesy of GENERAL MOTORS CORP.
3. Remove the fuel injector bracket bolts.
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Fig 9: Fuel Injector Bracket
Courtesy of GENERAL MOTORS CORP.
4. Install the J 44639 to the fuel injector brackets.
5. Pull back on the J 44639 in one steady motion, until the fuel injector breaks free from its seat.
6. Remove the J 44639 .
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Fig 10: Injector Removal Tool
Courtesy of GENERAL MOTORS CORP.
7. Remove the fuel injectors with the fuel injector brackets.
8. Remove the injector bracket pins.
9. Remove the copper washer from the injector bore and discard.
10. Remove the O-ring from the injector and discard.
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Fig 11: Injector O-Ring
Courtesy of GENERAL MOTORS CORP.
FUEL INJECTOR BALANCE TEST WITH TECH 2 (6.6L)
NOTE: For component locations, see
COMPONENT LOCATIONS .
Circuit Description
Fuel Injector Balance Test is performed when a misfire, knock, excessive smoke, or rough running condition
exists with no electrical Diagnostic Trouble Codes (DTCs). During test, Engine Control Module (ECM) turns
OFF individual injectors while engine is running and scan tool displays engine RPM. If a fuel injector is turned
OFF and there is a different engine speed change observed on scan tool when compared to other cylinders,
3
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that cylinder has a fuel injector or engine compression condition. If there is a balance rate of more than 4 mm3
or less than -4 mm3 on any cylinder, that cylinder has a fuel injector or engine compression condition. If a fuel
injector is turned OFF and engine noise or smoke disappears, that cylinder has a fuel injector or engine
compression condition.
Test Description
The numbers below refer to step numbers in diagnostic procedure.
3A balance rate between -4 mm3 and 4 mm3 will not cause a driveability concern. A balance rate
less than -4 mm3 , and between 4 mm3 and 14 mm3 will cause a driveability concern without any
DTCs. A balance rate of more than 15 mm3 will set a DTC.
4This step determines if ECM can control a stable fuel pressure. A high balance rate may be
caused by a fuel injector or compression only if ECM can control fuel pressure.
Diagnostic Procedure
1. Perform Diagnostic System Check - Engine Controls. See DIAGNOSTIC SYSTEM CHECK ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 6.6L SIERRA
& SILVERADO article. After performing Diagnostic System Check - Engine Controls, go to next
step.
2. Are any DTCs set other than P0300, P0301-P0308? If yes, go to DIAGNOSTIC TROUBLE CODE
DEFINITIONS in SELF-DIAGNOSTICS - 6.6L SIERRA & SILVERADO article. If no, go to next step.
NOTE: Balance rates may not register when
engine is off idle or engine coolant temperature is
less than 126°F (52°C).
3. Start and idle engine. Observe Balancing Rate Cyl. 1-8 parameters with scan tool. Are all Balancing
Rate parameters within -4 mm3 and 4 mm3 ? If yes, go to step 5. If no, go to next step.
4. Graph Fuel Pressure Regulator. See FUEL PRESSURE REGULATOR GRAPHING under FUEL
SYSTEM DIAGNOSIS - HIGH PRESSURE SIDE (6.6L). Is fuel pressure regulator graph normal? If
yes, go to step 6. If no, go to step 8.
NOTE: Fuel injector balance test must be
performed under conditions for which concern
occurred. Concern must be duplicated during test.
DO NOT operate cruise control during this test.
Cruise control reactivation after test may cause a
brief extreme increase in engine speed.
5. Observe engine speed or other customer concern. Perform Cylinder Power Balance Test in Special
Functions. Do any cylinders indicate a different engine speed change than the others, or lessen
customer concern? If yes, go to next step. If no, system is okay.
6. Perform engine compression test. Do any cylinders have low compression? If yes, repair as
necessary. See 6.6L V8 DIESEL article in ENGINES. If no, go to next step.
NOTE: Failure to correctly identify cylinder
positions may result in replacement of wrong fuel
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injector.
7. Replace faulty fuel injectors on cylinders that had poor RPM drop, high balance rates, or a
noise/smoke change. After repairs, go to step 9.
8. Replace fuel pressure regulator. After repairs, go to next step.
9. Operate vehicle under conditions in which concern occurred. Does system operate normally, with no
DTCs or symptoms? If yes, system is okay. If no, go to step 2.
Fuel Injector Sleeve Installation
Tools Required
J 45910 Fuel Injector Sleeve Remover/Installer
Important: Inspect the seating surface on the fuel injector sleeve and the fuel injector sleeve bore in the
cylinder head for debris or damage. If the fuel injector sleeve bore is damaged, the cylinder may need to be
replaced.
1. Clean the fuel injector sleeve lower sealing area (1) and the sleeve bore with GM P/N 12377981
(Canadian P/N 10953463).
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Fig 12: Fuel Injector Sleeve Lower Sealing Area
Courtesy of GENERAL MOTORS CORP.
2. Lubricate and install new O-rings (1) on the fuel injector sleeve (2).
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Fig 13: Fuel Injector Sleeve
Courtesy of GENERAL MOTORS CORP.
3. Install the fuel injector sleeve onto J 45910 .
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Fig 14: Installing Fuel Injector Sleeve To Fuel Injector Sleeve Remover/Installer
Courtesy of GENERAL MOTORS CORP.
4. Apply GM P/N 12345493, (Canadian P/N 10953488) or equivalent to the fuel injector sleeve lower
sealing area (1).
5. Install the fuel injector sleeve with J 45910 into the cylinder head.
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Fig 15: Installing Fuel Injector Sleeve Into Cylinder Head
Courtesy of GENERAL MOTORS CORP.
6. Lightly tap on J 45910 with a hammer to install and seat the fuel injector sleeve.
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Fig 16: Seating Fuel Injector Sleeve
Courtesy of GENERAL MOTORS CORP.
7. Remove J 45910 from the fuel injector sleeve.
Fuel Injectors Installation
1. Install a new O-ring onto the fuel injector.
2. Lubricate the O-ring with engine oil.
3. Install a new copper washer into the fuel injector bore in the cylinder head.
4. Install the fuel injector bracket pin.
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5. Install the fuel injector with fuel injector bracket.
6. Install the fuel injector bracket bolt. Tighten the fuel injector bracket bolt to 50 N.m (37 ft lbs).
Fig 17: Fuel Injector Bracket & Bolt
Courtesy of GENERAL MOTORS CORP.
7. Install the fuel injector return pipe assembly.
8. Install the fuel injector return line to injector eye bolts and washers. Lubricate the washers with
diesel fuel before installing. Tighten the fuel injector return line to injector eye bolts to 16 N.m (12 ft
lbs).
9. Install the fuel injector return line to cylinder head eye bolts and washers. Lubricate the washers
with diesel fuel before installing. Tighten the fuel injector return line to cylinder head eye bolts to 17
N.m (12 ft lbs).
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Fig 18: Fuel Injector Return Line
Courtesy of GENERAL MOTORS CORP.
From Engine To Injector Spill Lines
1. Disconnect fuel return line at engine. See QUICK CONNECT FITTINGS (METAL COLLAR) under
FUEL SYSTEMS in appropriate REMOVAL, OVERHAUL & INSTALLATION article.
2. Remove air duct from air cleaner assembly to turbo inlet.
3. Remove air intake pipe.
4. Remove fuel return rubber hose of fuel injection pump from junction block. Cap fitting on block with
a 3/8" rubber cap to prevent fuel leakage.
5. Install Vacuum Pump (J 23738-A) at fuel return pipe.
6. Apply 15 in. Hg of vacuum to pipe. If vacuum holds, go to step 13. If vacuum does not hold, go to
next step.
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7. Remove generator. See appropriate GENERATORS & REGULATORS article in STARTING &
CHARGING SYSTEMS.
8. Remove fuel return line connecting right front and left rear cylinder heads.
9. Install (J 23738-A) onto right front cylinder head return port.
10. Apply 15 in. Hg of vacuum to port. If vacuum holds, go to next step. If vacuum does not hold, leak is
in spill lines under valve cover. Install fuel return line between cylinder heads, remove lower right
valve cover, and go to step Link of FUEL LEAKS INSIDE OF ENGINE. For lower right side valve
cover removal and installation, see 6.6L V8 DIESEL article in ENGINES.
11. Install (J 23738-A) onto left rear cylinder head return port.
12. Apply 15 in. Hg of vacuum to port. If vacuum holds, replace leaking fuel return line between cylinder
heads. If vacuum does not hold, leak is in spill lines under valve cover. Install fuel return line
between cylinder heads, remove lower left valve cover, and go to step Link of FUEL LEAKS
INSIDE OF ENGINE. For lower left side valve cover removal and installation, see 6.6L V8 DIESEL
article in ENGINES.
13. Remove cap from junction block.
14. Reinstall fuel injection pump fuel return hose on junction block and clamp hose.
15. Install air duct on air cleaner assembly to turbo inlet.
16. Install air intake pipe.
17. Reinstall fuel return line to engine.
18. Install generator.
19. Start and idle engine and check for leaks.
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