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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 >> Fuel Injector Replacement (Left) >> 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.
    Fig 1: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  3. 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.
    4. IMPORTANT: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
    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.
  4. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
  5. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
    6. Fig 2: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
  7. Open the harness clip (2).
  8. Remove the main engine electrical harness connectors.
    9. Fig 3: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  9. Remove the engine harness main electrical connectors bolts.
  10. Remove the main electrical connectors from the bracket.
    11. Fig 4: View Of Main Electrical Connector Harness Bracket & Bolts
    GM1334948Courtesy of GENERAL MOTORS CORP.
  11. Disconnect the barometric sensor electrical connector.
  12. Remove the engine wire harness from the clip.
  13. Remove the main electrical harness bracket bolts.
  14. Remove the main electrical harness bracket.
    15. Fig 5: View Of Glow Plug Controller Electrical Connectors
    GM1335531Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the glow plug controller electrical connector.
    16. Fig 6: Glow Plug Controller Battery Feed Electrical Connector
    GM1409333Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the glow plug controller battery feed electrical connector (1).
  17. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Air Cleaner Outlet Duct Replacement .
    18. Fig 7: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
  18. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
  19. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    20. NOTE: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.
  20. Remove the left fuel injector pipes.
    21. Fig 8: View Of Fuel Return Hose & Injectors
    GM1335588Courtesy of GENERAL MOTORS CORP.
  21. Remove the fuel return hose clips.
  22. Remove the fuel return hose from the injectors.
    23. Fig 9: 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.
  23. Disconnect the fuel injector electrical connectors.
    24. Fig 10: View Of Left Fuel Injector Bracket Bolts
    GM1335618Courtesy of GENERAL MOTORS CORP.
  24. Remove the fuel injector bracket bolts.
    25. Fig 11: View Of Left Fuel Injectors W/Brackets
    GM1335621Courtesy of GENERAL MOTORS CORP.
  25. Install J-46594  into the bolt hole in the fuel injector bracket.
  26. Install a flare nut wrench onto J-46594  and pull back away from the fuel injector, until the injector releases from its seat.
  27. Remove J-46594  .
  28. Remove the fuel injectors with brackets.
    29. Fig 12: Identifying Fuel Injector Copper Washers
    GM1335628Courtesy of GENERAL MOTORS CORP.
  29. If necessary, remove the fuel injector bracket pins.
  30. If necessary, remove and discard the copper washer from the fuel injector bore.
  31. If necessary, remove and discard the O-ring from the fuel injector.
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