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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 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.
    Fig 1: View Of Left Fuel Rail And Bracket
    GM1335616Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. Install the fuel rail and bracket.
  2. Install the fuel rail bolts.

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

    3. Fig 2: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.
  3. Install the fuel injector pipes.

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

  4. After installing the fuel injector pipes, clean the injector pipes and apply sealant GM P/N 97720043, at the fittings to prevent moisture and debris from collecting between the line and fitting.
    5. Fig 3: View Of Left Fuel Rail At Pump Pipe
    GM1335603Courtesy of GENERAL MOTORS CORP.
  5. Remove the inlet fuel pipe.
  6. Connect the fuel inlet pipe to the injection pump.
  7. Connect the fuel inlet pipe to the fuel rail.

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

    8. Fig 4: View Of Fuel Pipe Assembly Bracket
    GM1335598Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel pipe bracket.
  9. Install the fuel pipe bracket bolts.

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

    10. Fig 5: View Of Distribution Block, Fuel Line Assembly & Bolts
    GM1335596Courtesy of GENERAL MOTORS CORP.
  10. Install the return/junction block and lines.
  11. Install the return/junction block fuel line clip bolts.

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

  12. Install the fuel hose to the fuel rail.
  13. Position the return/junction block hose clamp at the rear of the left fuel rail.
    14. Fig 6: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel hoses to the return/junction block.
  15. Position the return/junction block hose clamps at the injection pump.
    16. Fig 7: View Of Fuel Return Hose & Injectors
    GM1335588Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel injector return hose to the return/junction block line.
    17. Fig 8: View Of Fuel Rail Balance Pipe & Bolts
    GM1335586Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel rail balance pipe.
  18. Connect the fuel rail balance pipe to the fuel rails.

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

  19. Install the fuel rail balance pipe bolts.

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

    20. Fig 9: View Of Fuel Feed Pipe & Bolts
    GM1335584Courtesy of GENERAL MOTORS CORP.
  20. Install the fuel feed pipe.
  21. Install the fuel feed pipe nut/bolt.

    Tighten:  Tighten the nut/bolt to 25 N.m (18 lb ft).

  22. Install the banjo bolt and washer to the fuel injection control module.

    Tighten:  Tighten the bolt to 40 N.m (29 lb ft).

    23. Fig 10: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  23. Position the A/C compressor aside.
  24. Install the A/C compressor bolts.

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

  25. Install the PCV hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
    26. Fig 11: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  26. Install the fuel line bracket to the stud.
  27. Install the fuel line bracket nut.

    Tighten:  Tighten the nut to 21 N.m (15 lb ft).

  28. Connect the fuel feed and return line quick connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    29. Fig 12: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Lubricate the end of the duct prior to installation.
  29. Remove the tape from the turbocharger openings.
  30. Install the charged air cooler inlet duct connector (4) to the turbocharger.
  31. Tighten the charged air cooler inlet duct to turbocharger clamp (1).

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

    32. Fig 13: View Of Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  32. Position the junction block and bracket.
  33. Install the battery cable junction block bracket bolt (1) to the power steering pump bracket.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  34. Install the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LB7) Engine) or Water Outlet Tube Replacement (6.6L (LLY) Engine) in Engine Cooling.
  35. Connect 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.
  36. Prime the fuel system. Refer to Fuel System Priming .
  37. Start the engine. If the engine stalls, repeat the above step.
  38. Once the engine starts, inspect for fuel leaks.
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