Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Fuel Injection Pump: Installation
2004 Oldsmobile Bravada AWDSECTION Installation
WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
- Install the fuel injection pump. Install the fuel injection pump bolts to the front of the engine front cover. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Do not reuse old banjo bolt washers. Install NEW washers on both sides of banjo bolt fitting with bolt inserted through fitting. Connect the fuel return line banjo bolt at the junction block. Tighten the bolt to specification.
- Install the fuel supply hose and hose clamp to the fuel injection pump. Install fuel return hose and hose clamp to the fuel injection pump. Install high pressure lines to the injection pump to the junction block. Tighten the fittings to specification. Install the fuel pressure sensor connector at the junction block. Install the turbo water feed line/hoses as necessary. See Figure.
- Install the thermostat housing crossover. See THERMOSTAT HOUSING COVER under REMOVAL & INSTALLATION in 6.6L V-8 DIESEL article in ENGINES. Install air intake pipe. See AIR INTAKE PIPE under AIR INDUCTION SYSTEMS.
- Connect the engine wiring harness. Install upper radiator hose at outlet pipe using the following procedure: Install upper radiator hose mounting bolts and brackets. Tighten the bolts to specification. Install the upper radiator hose clamp. Install turbo cooling hose return and clamp. Install the left idler pulley and bolt. Install PCV catch tank, hose clamp and bolt to the right front of the engine. Install the thermostat housing bracket, wiring, fuel test port and nuts.
- Install the alternator positive cable and nut to alternator terminal stud. Tighten nut to specification. Slide the boot over the terminal stud. Install the alternator. Install the alternator bolts and tighten to specification. Connect the alternator electrical connector. Install a NEW "O" ring to the oil fill tube and lubricate the "O" ring with clean engine oil. Install the oil fill tube. Install the oil fill tube bolts and tighten to specification.
- Install the air conditioning/power steering bracket and bolts. Tighten the bolts to specification. Install the power steering pump. See appropriate POWER RECIRCULATING BALL article in STEERING. Install the air conditioning compressor. See appropriate article in AIR CONDITIONING & HEATING. Install the positive battery cable junction box and bolt.
- Install the drive belt. See 6.6L in COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article for drive belt routing. Install a 3/8 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. Route the drive belt over tension pulley. Slowly release the tension on the tensioner arm. Inspect for proper drive belt installation.
- Install the fan assembly. Install the fan clutch remover and installer set to the fan clutch. See Figure. Tighten the nut clockwise to specification. Install the upper fan shroud. See FAN SHROUD (UPPER) under MISCELLANEOUS. Refill the coolant. See COOLING SYSTEM BLEEDING under COOLING SYSTEMS.
- Install the air intake duct between the air cleaner and the turbocharger inlet housing. Connect the negative battery cables. Tighten battery cable bolts to specification. Replace all of the hold down ties. Prime fuel system. See FUEL SYSTEM PRIMING . Start the engine and check for leaks or noises. After the engine warms up, refill coolant reservoir to proper level.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.