How to Install an Injector on a 6.2L Diesel

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General Motors made an eight-cylinder 6.2 L diesel engine from 1982 until 1993. It was an optional engine that was most common on larger pickup trucks. The fuel injectors for this engine are on top of the engine, and each injector sends fuel to a cylinder in a specific sequence. The majority of the work of installing a fuel injector in a 6.2 L engine is removing the fuel lines so you can remove the old fuel injector.

Things You'll Need

  • Socket wrench set
  • GM part no. J-29664-1
  • Small pieces of cloth
  • GM special tool J-29873
  • Torque wrench
  • Disconnect the negative battery cable with a socket wrench to prevent anyone from starting the engine during the procedure. Remove the clip on the fuel return line, and detach the fuel return line from the fuel injectors.

  • Remove the air cleaner bracket from the valve cover with a socket wrench. Disconnect the crankcase ventilator bracket. Detach the fuel lines from the secondary fuel filter adapter and disconnect the secondary filter adapter. Release the clamp on the vacuum pump and move the pump aside to access the bolts for the intake manifold. Disconnect the intake manifold bolts and remove the intake manifold from the engine.

  • Cover the engine with GM part no. J-29664-1 to protect the open engine from debris. Disconnect the clips on the fuel injector lines from the loom brackets. Remove the fuel injector lines from the injector nozzles and place caps over the nozzles.

  • Detach the injector lines from the injector pump. Plug the open ends of the fuel lines with clean cloth to prevent contamination of the fuel lines.

  • Remove the fuel injector from the engine by turning the 30 mm hex portion of the fuel injector counterclockwise with GM special tool J-29873. Discard the gasket for the fuel injector.

  • Install a new fuel injector and gasket by turning the 30 mm hex portion of the injector clockwise with GM special tool J-29873. Tighten the injector to 50 foot-pounds with the special tool and a torque wrench.

  • Remove the cloth from the ends of the fuel lines and connect the fuel lines to the injectors. Tighten the retaining nut for the fuel line to 20 foot-pounds with a torque wrench. Complete the installation of the fuel injector by performing Steps 1 through 3 in reverse sequence.

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