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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 >> Fuel Rail Assembly Replacement - Bank 1 >> 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.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. Install the fuel rail and bolts.

    Tighten:  Tighten the bolts to 26 N.m (19 lb ft).

    2. Fig 1: Fuel Rail & Bolts (Bank 1)
    GM660456Courtesy of GENERAL MOTORS CORP.
  2. Install the fuel injector feed pipes.

    Tighten:  Tighten the fittings to 41 N.m (30 lb ft).

  3. Install the fuel injector feed pipe retainers and bolts.

    Tighten:  Tighten the bolts to 4 N.m (35 lb in).

    4. Fig 2: Left Fuel Injector Feed Pipes
    GM660451Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel junction block.

    Tighten:  Tighten the fittings to 25 N.m (18 lb ft).

    5. Fig 3: Fuel Junction Block
    GM660449Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel return rear pipe (1) to the back end of the fuel rail.

    Tighten:  Tighten the fitting to 44 N.m (32 lb ft).

    6. Fig 4: View Of Left Fuel Rail High Pressure Line & Left Cylinder Head Return Line Eye Bolt & Gasket
    GM660446Courtesy of GENERAL MOTORS CORP.
  6. Install the line from the junction block to the injection pump.

    Tighten:  Tighten the fitting to 40 N.m (30 lb ft).

    7. Fig 5: View Of Fuel Return Hose & Fuel Injection Pump High Pressure Line From Fuel Injection Pump
    GM660448Courtesy of GENERAL MOTORS CORP.
  7. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    8. Fig 6: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  8. Install drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  9. Install the water outlet pipe to thermostat housing.
  10. Install the PCV hose.
  11. Reposition the PCV hose clamp.
    12. Fig 7: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  12. Install the L-bracket holding the fuel lines.
  13. Connect the fuel lines.
  14. Install the glow plug bracket.
  15. Install the glow plug relay. Refer to Glow Plug Relay Replacement (Federal Emissions)  or Glow Plug Relay Replacement (California Emissions) .
  16. Connect the glow plug relay electrical connectors (1, 2, 3).
    17. Fig 8: Glow Plug Relay Electrical Connectors
    GM786978Courtesy of GENERAL MOTORS CORP.
  17. Install the charged air cooler inlet duct to the turbocharger.
  18. Align the mark on the duct (2) with the mark on the turbocharger.
  19. Position the clamp (1) as shown for proper clearance.

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

    20. Fig 9: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  20. Install the bolt attaching the positive battery cable junction box and bracket.
  21. Install the inlet hose to the water outlet tube.
  22. Install the inlet hose to the radiator.
  23. Reposition the inlet hose clamps.
    24. Fig 10: View Of Radiator Inlet Hose & Hose Clamps
    GM674532Courtesy of GENERAL MOTORS CORP.
  24. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  25. Connect the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  26. Replace all hold down ties.
  27. Start the engine and check for leaks or noises.
  28. After the engine warms up, refill the coolant reservoir to the proper level.
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