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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 >> 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 Battery Cable Junction Block Bolt At Power Steering Pump Bracket
    GM1409332Courtesy of GENERAL MOTORS CORP.
  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 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.
  3. Remove the battery cable junction block bracket bolt (1) from the power steering pump bracket.
  4. Reposition the junction block and bracket.
    5. Fig 2: View Of Turbocharger Clamp & Charged Air Cooler Inlet Duct Connector
    GM1334380Courtesy of GENERAL MOTORS CORP.
    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.
  5. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
  6. Remove the charged air cooler inlet duct connector (4) from the turbocharger.
    7. Fig 3: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel feed and return line quick connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  8. Remove the fuel line bracket nut.
  9. Remove the fuel line bracket from the stud.
  10. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Crankcase Ventilation Hoses/Pipes Replacement in Engine Mechanical - 6.6L (LLY).
    11. Fig 4: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  11. Remove the air conditioning (A/C) compressor bolts.
  12. Reposition the A/C compressor aside.
    13. Fig 5: View Of Fuel Feed Pipe & Bolts
    GM1335584Courtesy of GENERAL MOTORS CORP.
  13. Remove the banjo bolt and washer from the fuel injection control module.
  14. Remove the fuel feed pipe nuts/bolts.
  15. Remove the fuel feed pipe.
    16. Fig 6: View Of Fuel Rail Balance Pipe & Bolts
    GM1335586Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel rail balance pipe from the fuel rails.
  17. Remove the fuel rail balance pipe bolts.
  18. Remove the fuel rail balance pipe.
    19. Fig 7: View Of Fuel Return Hose & Injectors
    GM1335588Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the fuel injector return hose from the return/junction block line.
    20. Fig 8: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  20. Reposition the return/junction block hose clamps at the injection pump.
  21. Remove the fuel hoses from the return/junction block.
    22. Fig 9: View Of Distribution Block, Fuel Line Assembly & Bolts
    GM1335596Courtesy of GENERAL MOTORS CORP.
  22. Reposition the return/junction block hose clamp at the rear of the left fuel rail.
  23. Remove the fuel hose from the fuel rail.
  24. Remove the return/junction block fuel line clip bolts.
  25. Remove the return/junction block and lines.
    26. Fig 10: View Of Fuel Pipe Assembly Bracket
    GM1335598Courtesy of GENERAL MOTORS CORP.
  26. Remove the fuel pipe bracket bolts.
  27. Remove the fuel pipe bracket.
    28. Fig 11: View Of Left Fuel Rail At Pump Pipe
    GM1335603Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the fuel inlet pipe from the fuel rail.
  29. Disconnect the fuel inlet pipe from the injection pump.
  30. Remove the inlet fuel pipe.
    31. Fig 12: View Of Left Fuel Injector Pipes
    GM1335608Courtesy of GENERAL MOTORS CORP.
  31. 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.
  32. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal.
    33. 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.
  33. Remove the left fuel injector pipes.
    34. Fig 13: View Of Left Fuel Rail And Bracket
    GM1335616Courtesy of GENERAL MOTORS CORP.
  34. Remove the fuel rail bolts.
  35. Remove the fuel rail and bracket.
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