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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1023 (Engine Mechanical - 6.6L (Lb7) (Repair Instructions 1 Of 4)) >> Repair Instructions (On-Vehicle & Off Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Cylinder Head Replacement - Right >> Removal Procedure

Removal 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.
  1. Remove the right wheelhouse inner panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  2. Remove the turbocharger. Refer to Turbocharger Replacement .
  3. Loosen the charged air cooler outlet duct clamp at the charged air cooler.
  4. Remove the charged air cooler outlet duct (2).
    5. Fig 1: View Of Charged Air Cooler Outlet Duct & Clamp
    GM877289Courtesy of GENERAL MOTORS CORP.
  5. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (6.6L (LB7) Engine) in Engine Cooling.
  6. Remove the right fuel rail. Refer to Fuel Rail Assembly Replacement - Bank 1 in Engine Controls - 6.6L.
  7. Remove the right intake manifold. Refer to Intake Manifold Replacement - Right .
  8. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right (6.6L (LB7) Engine) in Engine Exhaust.
  9. Remove the valve rocker arm shaft, pushrods, and valve bridges. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement .
  10. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 in Engine Controls - 6.6L.
  11. Remove the fuel injector return pipe bolts and washers.
  12. Remove the fuel injector return pipe.
    13. Fig 2: View Of Fuel Injector Return Pipe
    GM660477Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel injector bracket bolts.
    14. Fig 3: View of Fuel Injector Bracket Bolts
    GM761229Courtesy of GENERAL MOTORS CORP.
  14. Install J 44639  to the fuel injector brackets.
  15. Pull back on the J 44639  in one steady motion, until the fuel injector breaks free from its seat.
    16. Fig 4: Breaking Fuel Injectors Free From Seat Using J 44639
    GM761230Courtesy of GENERAL MOTORS CORP.
  16. Remove the J 44639  .
  17. Remove the fuel injector with the brackets.
  18. Remove the injector locating pins.
    19. Fig 5: View Of Fuel Injectors, Brackets & Injector Locating Pins
    GM660480Courtesy of GENERAL MOTORS CORP.
  19. Remove the cylinder head bolts in the sequence shown and discard.
    20. Fig 6: Cylinder Head Bolts Removal Sequence
    GM660510Courtesy of GENERAL MOTORS CORP.
  20. Remove the cylinder head.
  21. Remove and discard the cylinder head gasket.
    22. Fig 7: View Of Cylinder Head & Gasket (Right)
    GM1336113Courtesy of GENERAL MOTORS CORP.
  22. Clean the sealing surface of the engine block and the cylinder head.
    23. NOTE: Clean all dirt, debris, and coolant from the engine block cylinder head bolt holes. Failure to remove all foreign material may result in damaged threads, improperly tightened fasteners or damage to components.
  23. Clean the cylinder head bolt holes in the engine block.
  24. For service to the cylinder head refer to the following:
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