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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 (Right) >> 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 Charged Air Cooler Outlet Duct
    GM1334381Courtesy of GENERAL MOTORS CORP.
  1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  2. 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.
  3. Remove the charged air cooler outlet duct from the intake.
  4. Remove the fuel filter and bracket. Refer to Fuel Filter Replacement .
  5. Remove the fuel injection control module (FICM). Refer to Fuel Injection Control Module Replacement .
    6. Fig 2: View Of Fuel Injector Pipes
    GM1335614Courtesy of GENERAL MOTORS CORP.
  6. 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.
  7. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    8. 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.
  8. Remove the fuel injector pipes.
    9. Fig 3: View Of Right Fuel Return Hose & Injectors
    GM1335592Courtesy of GENERAL MOTORS CORP.
  9. Remove the fuel return hose clips.
  10. Remove the fuel return hose from the injectors.
    11. Fig 4: 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.
  11. Disconnect the fuel injector electrical connectors.
    12. Fig 5: View Of Right Fuel Injector Bracket Bolts
    GM1335619Courtesy of GENERAL MOTORS CORP.
  12. Remove the fuel injector bracket bolts.
    13. Fig 6: View Of Right Fuel Injectors W/Brackets
    GM1335625Courtesy of GENERAL MOTORS CORP.
  13. Install J-46594  into the bolt hole in the fuel injector bracket.
  14. Install a flare nut wrench onto J-46594  and pull back away from the fuel injector, until the injector releases from its seat.
  15. Remove J-46594  .
  16. Remove the fuel injectors with brackets.
    17. Fig 7: Identifying Fuel Injector Copper Washers
    GM1335628Courtesy of GENERAL MOTORS CORP.
  17. If necessary, remove the fuel injector bracket pins.
  18. If necessary, remove and discard the copper washer from the fuel injector bore.
  19. If necessary, remove and discard the O-ring from the fuel injector.
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