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Home › Pontiac › 2002 › Aztek AWD › Repair and Diagnosis › External Pages › Different car › Section 917 (Engine Controls - 6.6L (LLY) (Introduction)) › Repair Instructions › Fuel Injection Pump Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Injection Pump
    GM1336114Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel injection pump to the block.
  2. Install the fuel injection pump bolts.

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

    3. Fig 2: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  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 Intake Manifold Replacement - Center in Engine Mechanical - 6.6L (LLY).
    6. Fig 3: View Of Left Fuel Rail At Pump Pipe
    GM1335603Courtesy of GENERAL MOTORS CORP.
  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. Fig 4: View Of Fuel Rail Balance Pipe & Bolts
    GM1335586Courtesy of GENERAL MOTORS CORP.
  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 (6.6L (LB7) Engine) or Thermostat Housing Crossover Replacement (6.6L (LLY) Engine) in Engine Cooling.
    11. Fig 5: View Of Generator Mounting Bracket
    GM1334912Courtesy of GENERAL MOTORS CORP.
  11. Install the generator bracket and bolts.

    Tighten:  Tighten the bolts to 46 N.m (34 lb ft).

  12. Install the generator. Refer to Generator Replacement (4.3L Engine) or Generator Replacement (4.8L, 5.3L, and 6.0L Engines) or Generator Replacement (6.6L (LB7) Engine) or Generator Replacement (6.6L (LLY) Engine) or Generator Replacement (8.1L Engine) in Engine Electrical.
    13. Fig 6: View Of Drive Belt Tensioner
    GM1334909Courtesy of GENERAL MOTORS CORP.
  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:  Tighten the bolt to 21 N.m (15 lb ft).

  15. Install the oil level indicator tube bracket bolt.

    Tighten:  Tighten the bolt to 21 N.m (15 lb ft).

    16. Fig 7: View Of A/C Compressor & Power Steering Pump Bracket
    GM1334867Courtesy of GENERAL MOTORS CORP.
  16. Install the A/C compressor/power steering pump bracket and bolts.

    Tighten:  Tighten the bolt to 46 N.m (34 lb ft).

    17. Fig 8: Rear Of The Power Steering Pump
    GM656330Courtesy of GENERAL MOTORS CORP.
  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 N.m (37 lb ft).

    19. Fig 9: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  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 N.m (37 lb ft).

  21. Connect the A/C cut out switch electrical connector.
  22. Connect the A/C compressor clutch electrical connector.
    23. Fig 10: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  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 in Engine Cooling.
  26. Install the fuel injection control module. Refer to Fuel Injection Control Module Replacement .
  27. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  28. Install the air cleaner outlet duct. Refer to Crankcase Ventilation Hoses/Pipes Replacement .
  29. Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) 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.
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