Engine Controls - Removal & Installation: Overhaul Chevrolet TrailBlazer I

AIR CLEANER ASSEMBLY

Note. Numbers in parentheses refer to numbers in illustrations.

FUEL RAIL ASSEMBLY

Note. Numbers in parentheses refer to numbers in illustrations.

Disassembly

1. Remove the fuel injectors. See «FUEL INJECTORS»(ref-159085-S27324403512003111100000) .
2. Remove the fuel pressure regulator. See «FUEL PRESSURE REGULATOR»(ref-159085-S36539169562003111100000) .
3. Remove the fuel injector harness from the fuel rail.

Assembly

1. Install the fuel injector harness to the fuel rail.
2. Install the fuel pressure regulator. See «FUEL PRESSURE REGULATOR»(ref-159085-S36539169562003111100000) .
3. Install the fuel injectors. See «FUEL INJECTORS»(ref-159085-S27324403512003111100000) .

1. Lubricate the new lower injector "O" ring seals (4) with clean engine oil. see scheme 95
2. Install the new "O" ring seals (4) on the spray tip end of each injector (3).
3. Install the fuel rail assembly. NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
4. Install the fuel rail attaching bolts. (Scheme 107) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
5. Connect the fuel feed and return pipes (1, 2) to the fuel rail. (Scheme 106) See «FUEL LINE DISCONNECT FITTINGS (4.2L)»(ref-159085-S23542063652003111100000).
6. Connect the fuel injector electrical connectors.
7. Connect the fuel pressure regulator vacuum line. (Scheme 105)
8. Install the intake manifold. See «INTAKE MANIFOLD»(ref-159085-S41547677022003111200000).
9. Connect the negative battery cable.
10. Inspect for leaks. Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

Scheme 105

Scheme 106

Scheme 107

1. Remove the EVAP vent valve (1). See «EVAP CANISTER VENT VALVE»(ref-159085-S41142516872003111100000) under MOTORS, RELAYS & SOLENOIDS. (Scheme 111)
2. Remove the fuel filter (8). See «FUEL FILTER»(ref-159085-S22621599902003111100000).
3. Disconnect the fuel feed and return pipes from the fuel sender (5). See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
4. Remove the fuel feed and return pipes from the retaining clip (7).
5. Remove the EVAP vent valve pipe.
6. Disconnect the EVAP vapor pipe from the fill limiter vent valve (4), and the front and rear rollover valves (2, 6). See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
7. Remove the EVAP vapor pipes.
8. Remove the fuel sender assembly (5) from the fuel tank. See «FUEL PUMP»(ref-159085-S15502040742003111100000).
9. Remove the EVAP canister (3). See «EVAP CANISTER»(ref-159085-S24518011622003111100000).

1. Install the EVAP canister (3). See «EVAP CANISTER»(ref-159085-S24518011622003111100000). (Scheme 111)
2. Install the fuel sender assembly (5) to the fuel tank. See «FUEL PUMP»(ref-159085-S15502040742003111100000).
3. Connect the EVAP vapor pipe to the fill limiter vent valve (4) and the front and rear rollover valve (2, 6). See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
4. Install the EVAP vent valve pipe.
5. Connect the fuel feed and return pipes to the fuel sender (5). See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
6. Install the fuel feed and return pipes to the retaining clip (7).
7. Install the fuel filter (8). See «FUEL FILTER»(ref-159085-S22621599902003111100000).
8. Install the EVAP vent valve (1). See «EVAP CANISTER VENT VALVE»(ref-159085-S41142516872003111100000) under MOTORS, RELAYS & SOLENOIDS.

Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. With the aid of an assistant, position and support the fuel tank.
2. Connect the fuel sender electrical connector (1). (Scheme 109)
3. Install the fuel tank straps (2). (Scheme 110)
4. Install the fuel tank strap bolts (1). Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
5. Remove the caps from the fuel and EVAP pipes.
6. Connect the fuel feed, return and EVAP pipes. See «FUEL LINE DISCONNECT FITTINGS (5.3L)»(ref-159085-S42498279002003111900000).
7. Connect the fuel tank pressure sensor electrical connector (3). (Scheme 109)
8. Connect the EVAP vent valve electrical connector (2).
9. Connect the fuel hose (2) to the fuel tank. (Scheme 108) Tighten the clamp (1) to specification. See «TORQUE SPECIFICATIONS»(ref-159085-S35886898402003111100000).
10. Lower the vehicle.
11. Refill the fuel tank.
12. Install the fuel fill cap.
13. Connect the negative battery cable.
14. Inspect for leaks. Turn the ignition ON, with the engine OFF for 10 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
15. Install the fuel tank shield, if equipped.
16. Install the frame brace.
17. Lower the vehicle.

Scheme 108

Scheme 109

Scheme 110

Scheme 111