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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 976 (Engine Controls - 6.6L (Lb7) (Introduction)) >> Repair Instructions >> Engine Wiring Harness Assembly 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.
  1. Install the engine wiring harness.
    2. Fig 1: Engine Wiring Harness
    GM660421Courtesy of GENERAL MOTORS CORP.
  2. Connect the fuel pressure regulator electrical connector (1).
    3. Fig 2: Fuel Pressure Regulator Electrical Connector
    GM786996Courtesy of GENERAL MOTORS CORP.
  3. Route the engine wiring harness to the engine.
  4. Raise the vehicle.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the engine wiring harness ground bolts (1).

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    6. Fig 3: Engine Harness Ground Bolts
    GM786972Courtesy of GENERAL MOTORS CORP.
  6. Connect the CMP sensor electrical connector (1).
    7. Fig 4: View Of CMP Sensor Electrical Connector & Cooling Fan Pulley
    GM742170Courtesy of GENERAL MOTORS CORP.
  7. Connect the CKP sensor electrical connector.
    8. Fig 5: CKP Sensor Electrical Connector
    GM786970Courtesy of GENERAL MOTORS CORP.
  8. Install the engine shield and bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    9. Fig 6: View Of Engine Protection Shield
    GM349061Courtesy of GENERAL MOTORS CORP.
  9. Lower the vehicle.
  10. Connect the fuel rail pressure sensor electrical connector (1).
    11. Fig 7: Fuel Rail Pressure Sensor Electrical Connector
    GM786994Courtesy of GENERAL MOTORS CORP.
  11. Connect the BARO sensor electrical connector (1).
    12. Fig 8: BARO Sensor Electrical Connector
    GM739503Courtesy of GENERAL MOTORS CORP.
  12. Connect the oil level sensor electrical connector (1).
    13. Fig 9: Oil Level Electrical Connector
    GM788846Courtesy of GENERAL MOTORS CORP.
  13. Install the left side engine harness to the glow plugs (1).
  14. Install the glow plug electrical nuts.

    Tighten:  Tighten the nuts to 2 N.m (18 lb in).

    15. Fig 10: Left Side Engine Harness At Glow Plugs
    GM788840Courtesy of GENERAL MOTORS CORP.
  15. Install the left inner wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  16. Install the fuel pipe retainer (2).
    17. Fig 11: Fuel Pipe Retainer
    GM788847Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel pipe retainer nut at the valve cover.

    Tighten:  Tighten the nut to 8 N.m (70 lb in).

  18. Connect the glow plug controller electrical connectors (1).
    19. Fig 12: Glow Plug Controller Electrical Connectors
    GM788841Courtesy of GENERAL MOTORS CORP.
  19. Connect the fuel rail temperature sensor electrical connector (1).
    20. Fig 13: Fuel Rail Temperature Sensor Electrical Connector
    GM786977Courtesy of GENERAL MOTORS CORP.
  20. Connect the left rear fuel injector electrical connector (1).
    21. Fig 14: Left Rear Fuel Injector Electrical Connector
    GM786988Courtesy of GENERAL MOTORS CORP.
  21. Connect the left front fuel injector electrical connector (1).
    22. Fig 15: Left Front Fuel Injector Electrical Connector
    GM786986Courtesy of GENERAL MOTORS CORP.
  22. Install the PCV hose to valve cover.
    23. Fig 16: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  23. Position the PCV hose clamp.
  24. Install the charged air cooler inlet duct to the turbocharger.
  25. Align the mark on the duct (2) with the mark on the turbocharger.
  26. Position the clamp (1) as shown for proper clearance.

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    27. Fig 17: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  27. Install the bulk connector bolts (1) to the bracket.

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

    28. Fig 18: View Of Engine-To-Chassis Harness Connector & Bracket Bolts
    GM674680Courtesy of GENERAL MOTORS CORP.
  28. Connect the engine harness electrical connectors.
    29. Fig 19: View Of Main Engine Harness Electrical Connectors
    GM674653Courtesy of GENERAL MOTORS CORP.
  29. Install the glow plug relay. Refer to Glow Plug Relay Replacement (Federal Emissions)  or Glow Plug Relay Replacement (California Emissions) .
  30. Install the turbocharger coolant bypass valve.

    Tighten:  Tighten the valve to 60 N.m (44 lb ft).

    31. Fig 20: View Of Turbocharger Bypass Valve & Washer
    GM687052Courtesy of GENERAL MOTORS CORP.
  31. Install the turbocharger water inlet hose.
  32. Position the turbocharger water inlet hose clamp.
    33. Fig 21: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS CORP.
  33. Connect the ECT sensor electrical connector (1).
    34. Fig 22: ECT Sensor Electrical Connector
    GM740506Courtesy of GENERAL MOTORS CORP.
  34. Install the engine sight shield hold-down bracket (1) and bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    35. Fig 23: Sight Shield Hold-Down Bolt & Bracket
    GM786983Courtesy of GENERAL MOTORS CORP.
  35. Connect the turbocharger boost sensor electrical connector (1).
    36. Fig 24: Turbocharger Boost Sensor Electrical Connector
    GM788842Courtesy of GENERAL MOTORS CORP.
  36. Connect the right front fuel injector electrical connector (1).
    37. Fig 25: Right Front Fuel Injector Electrical Connector
    GM788844Courtesy of GENERAL MOTORS CORP.
  37. Install the right side engine harness to the glow plugs (1).
  38. Install the right side glow plug electrical nuts.

    Tighten:  Tighten the nuts to 2 N.m (18 lb in).

    39. Fig 26: Right Side Engine Harness At Glow Plug
    GM788839Courtesy of GENERAL MOTORS CORP.
  39. Connect the EGR throttle valve solenoid electrical connector (1).
    40. Fig 27: EGR Throttle Valve Solenoid Electrical Connector
    GM788838Courtesy of GENERAL MOTORS CORP.
  40. Connect the EGR vacuum sensor electrical connector (1).
    41. Fig 28: EGR Valve Vacuum Sensor Electrical Connector
    GM788835Courtesy of GENERAL MOTORS CORP.
  41. Connect the EGR vent solenoid electrical connector (1).
    42. Fig 29: EGR Valve Vent Solenoid Electrical Connector
    GM788837Courtesy of GENERAL MOTORS CORP.
  42. Connect the EGR valve solenoid electrical connector (1).
    43. Fig 30: EGR Valve Solenoid Electrical Connector
    GM788836Courtesy of GENERAL MOTORS CORP.
  43. Connect the right rear fuel injector electrical connector (1).
    44. Fig 31: Right Rear Fuel Injector Electrical Connector
    GM786980Courtesy of GENERAL MOTORS CORP.
  44. Connect the following electrical connectors:
    • Water-in-fuel sensor (1)
    • Fuel heater (2)
    45. Fig 32: Water-In-Fuel Sensor & Fuel Heater
    GM786973Courtesy of GENERAL MOTORS CORP.
  45. Install the charged air cooler outlet duct to the intake.
  46. Tighten the charged air cooler outlet duct clamp (1).

    Tighten:  Tighten the clamp to 6 N.m (53 lb in).

    47. Fig 33: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  47. Connect the fuel injection control module electrical connectors (1).
    48. Fig 34: Fuel Injection Control Module Electrical Connectors
    GM786976Courtesy of GENERAL MOTORS CORP.
  48. Install the air cleaner. Refer to Air Cleaner Assembly Replacement .
  49. Connect the 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.
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