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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 >> 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. Disconnect 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.
  2. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement .
  3. Disconnect the fuel injection control module electrical connectors (1).
    4. Fig 1: Fuel Injection Control Module Electrical Connectors
    GM786976Courtesy of GENERAL MOTORS CORP.
  4. Loosen the charged air cooler outlet duct clamp (1).
    IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
  5. Remove the charged air cooler outlet duct.
    6. Fig 2: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the following electrical connectors:
    • Water-in-fuel sensor (1)
    • Fuel heater (2)
    7. Fig 3: Water-In-Fuel Sensor & Fuel Heater
    GM786973Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the right rear fuel injector electrical connector (1).
    8. Fig 4: Right Rear Fuel Injector Electrical Connector
    GM786980Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the exhaust gas recirculation (EGR) valve solenoid electrical connector (1).
    9. Fig 5: EGR Valve Solenoid Electrical Connector
    GM788836Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the EGR valve vent solenoid electrical connector (1).
    10. Fig 6: EGR Valve Vent Solenoid Electrical Connector
    GM788837Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the EGR valve vacuum sensor electrical connector (1).
    11. Fig 7: EGR Valve Vacuum Sensor Electrical Connector
    GM788835Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the EGR throttle valve solenoid electrical connector.
    12. Fig 8: EGR Throttle Valve Solenoid Electrical Connector
    GM788838Courtesy of GENERAL MOTORS CORP.
  12. Remove the right side glow plug electrical nuts.
  13. Remove the right side engine harness from the glow plug (1).
    14. Fig 9: Right Side Engine Harness At Glow Plug
    GM788839Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the right front fuel injector electrical connector (1).
    15. Fig 10: Right Front Fuel Injector Electrical Connector
    GM788844Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the turbocharger boost sensor electrical connector (1).
    16. Fig 11: Turbocharger Boost Sensor Electrical Connector
    GM788842Courtesy of GENERAL MOTORS CORP.
  16. Remove the sight shield hold-down bolt and bracket (1).
    17. Fig 12: Sight Shield Hold-Down Bolt & Bracket
    GM786983Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
    18. Fig 13: ECT Sensor Electrical Connector
    GM740506Courtesy of GENERAL MOTORS CORP.
  18. Reposition the turbocharger water inlet hose clamp.
  19. Remove the turbocharger water inlet hose.
    20. Fig 14: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS CORP.
  20. Remove the turbocharger coolant bypass valve.
    21. Fig 15: View Of Turbocharger Bypass Valve & Washer
    GM687052Courtesy of GENERAL MOTORS CORP.
  21. Remove the glow plug relay. Refer to Glow Plug Relay Replacement (Federal Emissions)  or Glow Plug Relay Replacement (California Emissions) .
  22. Disconnect the engine harness electrical connectors.
    23. Fig 16: View Of Main Engine Harness Electrical Connectors
    GM674653Courtesy of GENERAL MOTORS CORP.
  23. Remove the bulk connector bolts from the bracket (1).
    24. Fig 17: View Of Engine-To-Chassis Harness Connector & Bracket Bolts
    GM674680Courtesy of GENERAL MOTORS CORP.
  24. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
    IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
    25. Fig 18: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  25. Remove the charged air cooler inlet duct from the turbocharger.
  26. Reposition the positive crankcase ventilation (PCV) hose clamp.
  27. Remove the PCV hose from the left valve cover.
    28. Fig 19: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the left front fuel injector electrical connector (1).
    29. Fig 20: Left Front Fuel Injector Electrical Connector
    GM786986Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the left rear fuel injector electrical connector (1).
    30. Fig 21: Left Rear Fuel Injector Electrical Connector
    GM786988Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the fuel rail temperature sensor electrical connector (1).
    31. Fig 22: Fuel Rail Temperature Sensor Electrical Connector
    GM786977Courtesy of GENERAL MOTORS CORP.
  31. Disconnect the glow plug controller electrical connectors (1).
    32. Fig 23: Glow Plug Controller Electrical Connectors
    GM788841Courtesy of GENERAL MOTORS CORP.
  32. Remove the fuel pipe retainer nut at the valve cover.
  33. Remove the fuel pipe retainer (2).
    34. Fig 24: Fuel Pipe Retainer
    GM788847Courtesy of GENERAL MOTORS CORP.
  34. Remove the left front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
  35. Remove the left side glow plug electrical nuts.
  36. Remove the left side engine harness from the glow plugs (1).
    37. Fig 25: Left Side Engine Harness At Glow Plugs
    GM788840Courtesy of GENERAL MOTORS CORP.
  37. Disconnect the oil level electrical connector (1).
    38. Fig 26: Oil Level Electrical Connector
    GM788846Courtesy of GENERAL MOTORS CORP.
  38. Disconnect the barometric pressure (BARO) sensor electrical connector (1).
    39. Fig 27: BARO Sensor Electrical Connector
    GM739503Courtesy of GENERAL MOTORS CORP.
  39. Disconnect the fuel rail pressure sensor electrical connector (1).
    40. Fig 28: Fuel Rail Pressure Sensor Electrical Connector
    GM786994Courtesy of GENERAL MOTORS CORP.
  40. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  41. Remove the engine shield bolts and shield.
    42. Fig 29: View Of Engine Protection Shield
    GM349061Courtesy of GENERAL MOTORS CORP.
  42. Disconnect the crankshaft position (CKP) sensor electrical connector.
    43. Fig 30: CKP Sensor Electrical Connector
    GM786970Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the camshaft position (CMP) sensor electrical connector (1).
    44. Fig 31: View Of CMP Sensor Electrical Connector & Cooling Fan Pulley
    GM742170Courtesy of GENERAL MOTORS CORP.
  44. Remove the engine harness ground bolts (1).
    45. Fig 32: Engine Harness Ground Bolts
    GM786972Courtesy of GENERAL MOTORS CORP.
  45. Lower the vehicle.
  46. Unroute and lift up the engine wiring harness for access to fuel pressure regulator.
  47. Disconnect the fuel pressure regulator electrical connector (1).
    48. Fig 33: Fuel Pressure Regulator Electrical Connector
    GM786996Courtesy of GENERAL MOTORS CORP.
  48. Remove the engine wiring harness.
    49. Fig 34: Engine Wiring Harness
    GM660421Courtesy of GENERAL MOTORS CORP.
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