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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Controls - 6.6L (LLY) (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 intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  3. Remove both front wheelhouse panels. Refer to Wheelhouse Panel Replacement in Body Front End.
  4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
    Fig 1: View Of Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
  5. Loosen the charged air cooler outlet duct to intake hose clamp.
    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.
  6. Remove the charged air cooler outlet duct from the intake.
    7. Fig 2: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
    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.
  7. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
  8. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
    9. Fig 3: View Of Fuel Injection Control Module Electrical Connectors
    GM1334881Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel injection control module electrical connectors.
  10. Cut the tie strap attaching the harness to the bracket.
    11. Fig 4: View Of Left Glow Plug Harness Bracket Bolts
    GM1335443Courtesy of GENERAL MOTORS CORP.
  11. Remove the left glow plug harness bracket bolts.
    12. Fig 5: View Of Right Glow Plug Harness Bracket Bolts
    GM1335450Courtesy of GENERAL MOTORS CORP.
  12. Remove the right glow plug harness bracket bolts.
  13. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
    14. Fig 6: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    15. Fig 7: View Of EGR Valve Electrical Connector
    GM1335463Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
    16. Fig 8: View Of Camshaft Position Sensor Electrical Connector
    GM1334862Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the camshaft position (CMP) sensor electrical connector.
    17. Fig 9: View Of Ground Bolts
    GM1335467Courtesy of GENERAL MOTORS CORP.
  17. Remove the 2 ground bolts.
    18. Fig 10: View Of Crankshaft Position Sensor Electrical Connector
    GM1335470Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the crankshaft position (CKP) sensor electrical connector.
    19. Fig 11: View Of Electrical Harness Tie Strap
    GM1335476Courtesy of GENERAL MOTORS CORP.
  19. Remove the tie strap from the electrical harness.
    20. Fig 12: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  21. Open the harness clip (2).
  22. Remove the main engine electrical harness connectors.
    23. Fig 13: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the barometric sensor electrical connector.
    24. Fig 14: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  24. Remove the main engine electrical harness connector bolts.
    25. Fig 15: View Of Fuel Pressure Control Valve Electrical Connector
    GM1335482Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the fuel pressure control valve electrical connector.
    26. Fig 16: View Of Turbocharger Boost Sensor Electrical Connector
    GM1335490Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the turbocharger boost sensor electrical connector.
    27. Fig 17: View Of Oil Level Sensor Electrical Harness Connector
    GM1335526Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the oil level sensor electrical harness connector.
    28. Fig 18: View Of Fuel Temperature Sensor Electrical Connector
    GM1335528Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the fuel temperature sensor electrical connector.
    29. Fig 19: View Of Glow Plug Controller Electrical Connectors
    GM1335531Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the glow plug controller electrical connector.
    30. Fig 20: Glow Plug Controller Battery Feed Electrical Connector
    GM1409333Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the glow plug controller battery feed electrical connector (1).
    31. Fig 21: View Of Turbocharger Vane Position Sensor And Electrical Connector
    GM1334926Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note the wire routing prior to removal.
  31. Disconnect and remove the turbocharger vane position sensor.
    32. Fig 22: View Of Fuel Injector Electrical Connectors
    GM1335536Courtesy of GENERAL MOTORS CORP.
    NOTE: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage.
  32. Disconnect the fuel injector electrical connectors.
    33. Fig 23: View Of Turbocharger Vane Control Solenoid Valve & Electrical Connector
    GM1335540Courtesy of GENERAL MOTORS CORP.
  33. Disconnect the turbocharger vane control solenoid valve.
    34. Fig 24: View Of Fuel Rail Pressure Sensor And Electrical Connector
    GM1335543Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the fuel rail pressure sensor electrical connector.
    35. Fig 25: View Of Oil Pressure Sensor Electrical Connector
    GM1335546Courtesy of GENERAL MOTORS CORP.
  35. Disconnect the oil pressure sensor electrical connector.
    36. Fig 26: View Of Oil Level Sensor Harness Bolt
    GM1335549Courtesy of GENERAL MOTORS CORP.
  36. Remove the oil level sensor harness bolt.
    37. Fig 27: View Of Glow Plug Controller Bolts
    GM1336490Courtesy of GENERAL MOTORS CORP.
  37. Remove the glow plug controller bolts.
  38. Remove the glow plug controller.
  39. Remove the glow plug electrical connector nuts.
    40. Fig 28: View Of Fuel Injector Control Module Harness
    GM1335560Courtesy of GENERAL MOTORS CORP.
  40. Remove the engine wiring harness.
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