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Home › Pontiac › 2002 › Aztek AWD › Repair and Diagnosis › External Pages › Different car › Section 916 (Engine Controls - 6.6L (Lb7) (Introduction)) › Repair Instructions › Fuel Junction Block Replacement › 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.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  1. Install the fuel junction block and nuts.

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

  2. Install the fuel pipe junction block to the fuel rail (1).

    Tighten:  Tighten the bolt to 15 N.m (11 lb ft).

  3. Connect the fuel pipes (3) to the junction block.

    Tighten:  Tighten the fittings to 44 N.m (32 lb ft).

    4. Fig 1: Fuel Injection Block Banjo Bolt, Fuel Pipe & Nuts
    GM755766Courtesy of GENERAL MOTORS CORP.
  4. Connect the fuel pipe junction block to the fuel rail (1).

    Tighten:  Tighten the fitting to 44 N.m (32 lb ft).

    5. Fig 2: Fuel Pipe Junction Block At Fuel Rail
    GM755759Courtesy of GENERAL MOTORS CORP.
  5. Install the charged air cooler inlet duct to the turbocharger.
  6. Align the mark on the duct (2) with the mark on the turbocharger.
  7. Position the clamp (1) as shown for proper clearance.

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

    8. Fig 3: View Of Charged Air Cooler Inlet Duct & Clamps
    GM877281Courtesy of GENERAL MOTORS CORP.
  8. Install the PCV hose to the upper valve rocker arm cover.
  9. Reposition the PCV hose clamp.
    10. Fig 4: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  10. Install the water outlet tube using the following procedure:
    1. Install a new O-ring seal on the water outlet tube.
    2. Lightly lubricate the O-ring seal with coolant.
    3. Install the water outlet tube.
    4. Install the bolt attaching the water outlet tube to the thermostat housing.

      Tighten:  Tighten the bolt to 21 N.m (16 lb ft).

    5. Install the bolts attaching the water outlet tube to the rocker arm cover.

      Tighten:  Tighten the bolts to 21 N.m (16 lb ft).

    11. Fig 5: Water Outlet Tube & Bolt
    GM699329Courtesy of GENERAL MOTORS CORP.
  11. Install the turbocharger coolant hose and clamp to the turbocharger bypass valve.
  12. Connect the oil pressure sending unit electrical connector.
    13. Fig 6: View Of Turbocharger Inlet Coolant Hose
    GM668427Courtesy of GENERAL MOTORS CORP.
  13. Connect the left front injector harness electrical connector (1).
    14. Fig 7: Left Front Injector Harness Electrical Connector
    GM759733Courtesy of GENERAL MOTORS CORP.
  14. Install the A/C compressor using the following procedure:
    1. Install the A/C compressor bolts.

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

    2. Connect the A/C cut out switch electrical connector.
    3. Connect the A/C compressor clutch electrical connector.
    15. Fig 8: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  15. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  16. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  17. Install the upper intake manifold cover.
  18. Install the upper intake manifold cover to the outlet duct.
  19. Tighten the outlet duct clamp at the upper intake manifold cover.

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

    20. Fig 9: View Of Upper Intake Manifold Cover, Outlet Duct & Clamp
    GM813243Courtesy of GENERAL MOTORS CORP.
  20. 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.
  21. Position the hood in the normal operating position by moving the hood hinge bolts from the service position (2) to the normal operating position (1).

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

    22. Fig 10: Identifying Hood Hinge Normal And Service Position Bolt Holes
    GM310799Courtesy of GENERAL MOTORS CORP.
  22. Purge air from the fuel system.
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