Removal (Bank 1)
WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cables from both batteries. Drain coolant. See DRAINING & REFILLING COOLING SYSTEM . Remove upper radiator hose and two hose clamps. Remove bolt holding positive battery cable junction box and bracket and move it out of way.
- Tape turbocharger to keep foreign material out. Remove turbocharger air outlet hose. Disconnect 3 glow plug relay connectors. Remove glow plug bracket. Disconnect both 40-pin and 24-pin engine connectors. Remove engine connector bracket and set aside. Disconnect fuel in-line and return lines. Remove L-bracket holding fuel lines.
- Remove PCV hose and clamp, and move out of way. Remove water pipe outlet from thermostat housing. Remove serpentine belt. Remove bolts holding air conditioning compressor and flip unit aside. Remove line from junction block to injection pump.
- Loosen high pressure line at back end of fuel rail and remove. Remove junction block assembly. Loosen high pressure injection lines at four injectors first. Loosen high pressure injection lines at 4 fittings on fuel rail. Mark high pressure injection lines in order and remove them. Remove 3 bolts holding the fuel rail and remove.