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Home >> GMC >> 2001 >> Sierra 2500 HD, 2D Pickup, 6.6 1, 4WD, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 6.6L - Repair Instructions >> Repair Instructions >> Fuel Junction Block Replacement >> Removal Procedure

Removal Procedure

    Fig 1: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS COMPANY
  1. Move the hood to the service position, by moving the hood hinge bolts (1) to the service positions (2).
  2. Disconnect the batteries negative cables. Refer to Battery Negative Cable Disconnection and Connection (Auxiliary Battery) , Battery Negative Cable Disconnection and Connection (Single Battery) in Engine Electrical.
    3. Fig 2: Upper Intake Manifold Sight Shield
    GM658266Courtesy of GENERAL MOTORS COMPANY
  3. Remove the upper intake sight shield using the following procedure:
    1. Remove the retaining bolt in the front of the shield.
    2. Lift up on the front of the shield.
    3. Lift the shield off the rear bracket.
  4. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
    6. Fig 3: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS COMPANY
  6. Relocate the air conditioning (A/C) compressor using the following procedure:
    1. Disconnect the A/C compressor clutch electrical connector.
    2. Disconnect the A/C cut out switch electrical connector.
    3. Remove the A/C compressor mounting bolts.
    4. Reposition the A/C compressor with the hoses attached to the right side of the engine compartment.
    7. Fig 4: Left Front Injector Harness Electrical Connector
    GM759733Courtesy of GENERAL MOTORS COMPANY
  7. Disconnect the left front injector harness connector (1).
  8. Disconnect the oil pressure sending unit harness connector.
    9. Fig 5: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS COMPANY
  9. Disconnect the turbocharger coolant hose and clamp from the turbocharger bypass valve.
    10. Fig 6: View Of Water Outlet & Bolts
    GM699329Courtesy of GENERAL MOTORS COMPANY
  10. Disconnect the water outlet tube using the following procedure:
    1. Remove the 2 bolts retaining the water outlet tube to the left valve rocker arm cover.
    2. Remove the bolt retaining the water outlet tube to the thermostat housing.
    3. Remove the water outlet tube.
    4. Remove and discard the O-ring seal.
    11. Fig 7: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS COMPANY
  11. Disconnect the positive crankcase ventilation (PCV) hose from the upper valve rocker arm cover.
    12. Fig 8: Turbocharged Air Hose View
    GM664853Courtesy of GENERAL MOTORS COMPANY
    IMPORTANT:

    Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.

  12. Loosen the charged air cooler inlet duct to turbocharger clamp and remove the inlet duct.
    13. Fig 9: Fuel Injection Block Banjo Bolt, Fuel Pipe & Nuts
    GM755766Courtesy of GENERAL MOTORS COMPANY
  13. Disconnect the banjo bolt (1) from the junction block.
  14. Disconnect the 3 fuel pipes (3) from the junction block.
    15. Fig 10: Fuel Pipe Junction Block At Fuel Rail
    GM755759Courtesy of GENERAL MOTORS COMPANY
  15. Disconnect the other end of fuel pipe junction block to the fuel rail (1).
  16. Remove the 2 nuts holding the junction block.
  17. Remove the junction block.
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