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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 973 (ENGINE CONTROLS - 6.6L (LB7) (INTRODUCTION))REPAIR INSTRUCTIONSFUEL RAIL FUEL FEED PIPE REPLACEMENT - RIGHTINSTALLATION PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Installation Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION 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.
  1. Install the fuel rail feed pipe to the right fuel rail.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the fuel rail feed pipe to the junction block

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

  3. Install the fuel rail feed pipe bracket
    4. Fig 1: Right Fuel Rail Feed Pipe Between Junction Block & Right Fuel Rail
    GM791898Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel injection pump to junction block fuel feed front pipe.

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

    5. Fig 2: Junction Block To Fuel Injection Pump Fuel Feed Pipe
    GM791907Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel feed front pipe (1).
  6. Remove the fuel feed front pipe bracket nut.

    Tighten:  Tighten the nut to 8 N.m (70 lb in).

    7. Fig 3: Fuel Feed Front Hose To Fuel Feed Front
    GM791983Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel lines to the chassis pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  8. 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.
  9. Install the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
  10. Install the charged air cooler inlet duct to turbocharger.
  11. Align the mark on the duct (2) with the mark on the turbocharger.
  12. Position the clamp (1) as shown for proper clearance.

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

    13. Fig 4: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  13. Install the charged air cooler outlet duct to the intake.
  14. Align the mark on the duct (3) with the mark on the turbocharger.
  15. Position the clamp (1) as shown for proper clearance.

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

    16. Fig 5: View Of Charged Air Cooler Outlet Duct & Clamps
    GM877275Courtesy of GENERAL MOTORS CORP.
  16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  17. 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.
  18. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.