Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Fuel Pressure Regulator

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Removal & Installation



  1. Remove the air intake pipe.
  2.  
  3. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  4.  
  5. Disconnect the A/C cut out switch electrical connector.
  6.  
  7. Remove the A/C compressor bolts.
  8.  
  9. Remove the alternator.
  10.  
  11. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.
  12.  
  13. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.

    Click image to see an enlarged view

    Fig. Main engine electrical harness connector

  14.  
  15. Open the harness clip (2).
  16.  
  17. Remove the main engine electrical harness connectors.
  18.  
  19. Disconnect the barometric pressure (BARO) sensor electrical connector.
  20.  
  21. Remove the main engine harness electrical connector bolts.
  22.  
  23. Remove the main connectors from the bracket.
  24.  
  25. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  26.  
  27. Remove the water outlet tube.
  28.  
  29. Disconnect the fuel temperature sensor electrical connector.
  30.  
  31. Disconnect the fuel pressure regulator electrical connector.
  32.  
  33. Disconnect the oil level sensor harness electrical connector.
  34.  
  35. Reposition the distribution block hose clamps.
  36.  
  37. Remove the distribution block hoses from the distribution block.

    Click image to see an enlarged view

    Fig. Remove the distribution block hoses from the distribution block

  38.  
  39. Remove the Exhaust Gas Recirculation (EGR) coolant pipe bolts.
  40.  
  41. Loosen the EGR coolant pipe clamp and position the hose aside.
  42.  
  43. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
  44.  
  45. Using compressed air, thoroughly blow dry the regulator and pump.
  46.  
  47. Remove the 3 fuel pressure regulator screws using a T25 TORX®.
  48.  
  49. Remove the fuel pressure regulator.
  50.  
  51. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:
    1. Place a clean rag over the bore on order to collect the excess fuel
    2.  
    3. Bump the engine over in order to flush any debris out of the regulator bore
    4.  

  52.  

To install:


NOTE
If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.

  1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.
    WARNING
    If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage.

  2.  
  3. Install the fuel pressure regulator.
  4.  
  5. Install the 3 fuel pressure regulator screws using a T25 TORX®, as follows:
    1. Tighten the screws a first pass to 35 inch lbs. (4 Nm).
    2.  
    3. Tighten the screws a final pass to 62 inch lbs. (7 Nm).
    4.  

  6.  
  7. Position the EGR coolant pipe clamp and install the coolant pipe to the thermostat housing.
  8.  
  9. Install the EGR coolant pipe retaining bolts and tighten to 15 ft. lbs. (21 Nm).
  10.  
  11. Install the distribution block hoses to the distribution block.

    Click image to see an enlarged view

    Fig. Connect the distribution block hoses from the distribution block

  12.  
  13. Position the distribution block hose clamps.
  14.  
  15. Connect the oil level sensor harness electrical connector.
  16.  
  17. Connect the fuel pressure regulator electrical connector.
  18.  
  19. Connect the fuel temperature sensor electrical connector.
  20.  
  21. Install the water outlet tube.
  22.  
  23. Connect the ECT sensor electrical connector.
  24.  
  25. Install the main connectors to the bracket.
  26.  
  27. Install the main engine harness electrical connector bolts:
    1. Tighten the bolts to 15 ft. lbs. (21 Nm).
    2.  

  28.  
  29. Connect the BARO sensor electrical connector.
  30.  
  31. Connect the main engine electrical harness connectors.
  32.  
  33. Push down on the latches (1) in order to connect the connectors.
  34.  
  35. Close the harness clip (2).

    Click image to see an enlarged view

    Fig. Main engine electrical harness connector

  36.  
  37. Position the A/C compressor.
  38.  
  39. Install the A/C compressor bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  40.  
  41. Connect the A/C cut out switch electrical connector.
  42.  
  43. Connect the A/C compressor clutch electrical connector.
  44.  
  45. Install the alternator.
  46.  
  47. Install the air intake pipe.
  48.  
  49. Prime the fuel system.
  50.  
  51. Start the engine. If the engine stalls, repeat the above step.
  52.  
  53. Once the engine starts, inspect for fuel leaks.
  54.  

  1. Remove the air intake pipe.
  2.  
  3. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  4.  
  5. Disconnect the A/C cut out switch electrical connector.
  6.  
  7. Remove the A/C compressor bolts.
  8.  
  9. Remove the alternator.
  10.  
  11. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.
  12.  
  13. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.

    Click image to see an enlarged view

    Fig. Main engine electrical harness connector

  14.  
  15. Open the harness clip (2).
  16.  
  17. Remove the main engine electrical harness connectors.
  18.  
  19. Disconnect the barometric pressure (BARO) sensor electrical connector.
  20.  
  21. Remove the main engine harness electrical connector bolts.
  22.  
  23. Remove the main connectors from the bracket.
  24.  
  25. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  26.  
  27. Remove the water outlet tube.
  28.  
  29. Disconnect the fuel temperature sensor electrical connector.
  30.  
  31. Disconnect the fuel pressure regulator electrical connector.
  32.  
  33. Disconnect the oil level sensor harness electrical connector.
  34.  
  35. Reposition the distribution block hose clamps.
  36.  
  37. Remove the distribution block hoses from the distribution block.

    Click image to see an enlarged view

    Fig. Remove the distribution block hoses from the distribution block

  38.  
  39. Remove the Exhaust Gas Recirculation (EGR) coolant pipe bolts.
  40.  
  41. Loosen the EGR coolant pipe clamp and position the hose aside.
  42.  
  43. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
  44.  
  45. Using compressed air, thoroughly blow dry the regulator and pump.
  46.  
  47. Remove the 3 fuel pressure regulator screws using a T25 TORX®.
  48.  
  49. Remove the fuel pressure regulator.
  50.  
  51. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:
    1. Place a clean rag over the bore on order to collect the excess fuel
    2.  
    3. Bump the engine over in order to flush any debris out of the regulator bore
    4.  

  52.  

To install:


NOTE
If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.

  1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.
    WARNING
    If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage.

  2.  
  3. Install the fuel pressure regulator.
  4.  
  5. Install the 3 fuel pressure regulator screws using a T25 TORX®, as follows:
    1. Tighten the screws a first pass to 35 inch lbs. (4 Nm).
    2.  
    3. Tighten the screws a final pass to 62 inch lbs. (7 Nm).
    4.  

  6.  
  7. Position the EGR coolant pipe clamp and install the coolant pipe to the thermostat housing.
  8.  
  9. Install the EGR coolant pipe retaining bolts and tighten to 15 ft. lbs. (21 Nm).
  10.  
  11. Install the distribution block hoses to the distribution block.

    Click image to see an enlarged view

    Fig. Connect the distribution block hoses from the distribution block

  12.  
  13. Position the distribution block hose clamps.
  14.  
  15. Connect the oil level sensor harness electrical connector.
  16.  
  17. Connect the fuel pressure regulator electrical connector.
  18.  
  19. Connect the fuel temperature sensor electrical connector.
  20.  
  21. Install the water outlet tube.
  22.  
  23. Connect the ECT sensor electrical connector.
  24.  
  25. Install the main connectors to the bracket.
  26.  
  27. Install the main engine harness electrical connector bolts:
    1. Tighten the bolts to 15 ft. lbs. (21 Nm).
    2.  

  28.  
  29. Connect the BARO sensor electrical connector.
  30.  
  31. Connect the main engine electrical harness connectors.
  32.  
  33. Push down on the latches (1) in order to connect the connectors.
  34.  
  35. Close the harness clip (2).

    Click image to see an enlarged view

    Fig. Main engine electrical harness connector

  36.  
  37. Position the A/C compressor.
  38.  
  39. Install the A/C compressor bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  40.  
  41. Connect the A/C cut out switch electrical connector.
  42.  
  43. Connect the A/C compressor clutch electrical connector.
  44.  
  45. Install the alternator.
  46.  
  47. Install the air intake pipe.
  48.  
  49. Prime the fuel system.
  50.  
  51. Start the engine. If the engine stalls, repeat the above step.
  52.  
  53. Once the engine starts, inspect for fuel leaks.
  54.  

6.6L Engine
  1. Remove the air intake pipe.
  2.  
  3. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
  4.  
  5. Disconnect the A/C cut out switch electrical connector.
  6.  
  7. Remove the A/C compressor bolts.
  8.  
  9. Remove the alternator.
  10.  
  11. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.
  12.  
  13. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.

    Click image to see an enlarged view

    Fig. Main engine electrical harness connector

  14.  
  15. Open the harness clip (2).
  16.  
  17. Remove the main engine electrical harness connectors.
  18.  
  19. Disconnect the barometric pressure (BARO) sensor electrical connector.
  20.  
  21. Remove the main engine harness electrical connector bolts.
  22.  
  23. Remove the main connectors from the bracket.
  24.  
  25. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  26.  
  27. Remove the water outlet tube.
  28.  
  29. Disconnect the fuel temperature sensor electrical connector.
  30.  
  31. Disconnect the fuel pressure regulator electrical connector.
  32.  
  33. Disconnect the oil level sensor harness electrical connector.
  34.  
  35. Reposition the distribution block hose clamps.
  36.  
  37. Remove the distribution block hoses from the distribution block.

    Click image to see an enlarged view

    Fig. Remove the distribution block hoses from the distribution block

  38.  
  39. Remove the exhaust gas recirculation (EGR) coolant pipe bolts.
  40.  
  41. Loosen the EGR coolant pipe clamp and position the hose aside.
  42.  
  43. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
  44.  
  45. Using compressed air, thoroughly blow dry the regulator and pump.
  46.  
  47. Remove the 3 fuel pressure regulator screws using a T25 TORX®.
  48.  
  49. Remove the fuel pressure regulator.
  50.  
  51. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:
    1. Place a clean rag over the bore on order to collect the excess fuel
    2.  
    3. Bump the engine over in order to flush any debris out of the regulator bore
    4.  

  52.  

To install:


NOTE
If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.

  1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.
    WARNING
    If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage.

  2.  
  3. Install the fuel pressure regulator.
  4.  
  5. Install the 3 fuel pressure regulator screws using a T25 TORX®, as follows:
    1. Tighten the screws a first pass to 35 inch lbs. (4 Nm).
    2.  
    3. Tighten the screws a final pass to 62 inch lbs. (7 Nm).
    4.  

  6.  
  7. Position the EGR coolant pipe clamp and install the coolant pipe to the thermostat housing.
  8.  
  9. Install the EGR coolant pipe retaining bolts and tighten to 15 ft. lbs. (21 Nm).
  10.  
  11. Install the distribution block hoses to the distribution block.

    Click image to see an enlarged view

    Fig. Connect the distribution block hoses from the distribution block

  12.  
  13. Position the distribution block hose clamps.
  14.  
  15. Connect the oil level sensor harness electrical connector.
  16.  
  17. Connect the fuel pressure regulator electrical connector.
  18.  
  19. Connect the fuel temperature sensor electrical connector.
  20.  
  21. Install the water outlet tube.
  22.  
  23. Connect the ECT sensor electrical connector.
  24.  
  25. Install the main connectors to the bracket.
  26.  
  27. Install the main engine harness electrical connector bolts:
    1. Tighten the bolts to 15 ft. lbs. (21 Nm).
    2.  

  28.  
  29. Connect the BARO sensor electrical connector.
  30.  
  31. Connect the main engine electrical harness connectors.
  32.  
  33. Push down on the latches (1) in order to connect the connectors.
  34.  
  35. Close the harness clip (2).

    Click image to see an enlarged view

    Fig. Main engine electrical harness connector

  36.  
  37. Position the A/C compressor.
  38.  
  39. Install the A/C compressor bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  40.  
  41. Connect the A/C cut out switch electrical connector.
  42.  
  43. Connect the A/C compressor clutch electrical connector.
  44.  
  45. Install the alternator.
  46.  
  47. Install the air intake pipe.
  48.  
  49. Prime the fuel system.
  50.  
  51. Start the engine. If the engine stalls, repeat the above step.
  52.  
  53. Once the engine starts, inspect for fuel leaks.
  54.  

 
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