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

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

Fuel Pressure Regulator

REMOVAL & INSTALLATION

6.6L Engine

1. Remove the air intake pipe.

2. Disconnect the air conditioning (A/C) compressor clutch electrical connector.

3. Disconnect the A/C cut out switch electrical connector.

4. Remove the A/C compressor bolts.

5. Remove the alternator.

6. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.

7. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.

Fig. Main engine electrical harness connector

8. Open the harness clip (2).

9. Remove the main engine electrical harness connectors.

10. Disconnect the barometric pressure (BARO) sensor electrical connector.

11. Remove the main engine harness electrical connector bolts.

12. Remove the main connectors from the bracket.

13. Disconnect the engine coolant temperature (ECT) sensor electrical connector.

14. Remove the water outlet tube.

15. Disconnect the fuel temperature sensor electrical connector.

16. Disconnect the fuel pressure regulator electrical connector.

17. Disconnect the oil level sensor harness electrical connector.

18. Reposition the distribution block hose clamps.

19. Remove the distribution block hoses from the distribution block.

Fig. Remove the distribution block hoses from the distribution block

20. Remove the exhaust gas recirculation (EGR) coolant pipe bolts.

21. Loosen the EGR coolant pipe clamp and position the hose aside.

22. 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.

23. Using compressed air, thoroughly blow dry the regulator and pump.

24. Remove the 3 fuel pressure regulator screws using a T25 TORX®.

25. Remove the fuel pressure regulator.

26. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:

a. Place a clean rag over the bore on order to collect the excess fuel

b. Bump the engine over in order to flush any debris out of the regulator bore

27.

28.

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. Install the fuel pressure regulator.

3. Install the 3 fuel pressure regulator screws using a T25 TORX®, as follows:

a. Tighten the screws a first pass to 35 inch lbs. (4 Nm).

b. Tighten the screws a final pass to 62 inch lbs. (7 Nm).

4.

5.

6. Position the EGR coolant pipe clamp and install the coolant pipe to the thermostat housing.

7. Install the EGR coolant pipe retaining bolts and tighten to 15 ft. lbs. (21 Nm).

8. Install the distribution block hoses to the distribution block.

Fig. Connect the distribution block hoses from the distribution block

9. Position the distribution block hose clamps.

10. Connect the oil level sensor harness electrical connector.

11. Connect the fuel pressure regulator electrical connector.

12. Connect the fuel temperature sensor electrical connector.

13. Install the water outlet tube.

14. Connect the ECT sensor electrical connector.

15. Install the main connectors to the bracket.

16. Install the main engine harness electrical connector bolts:

a. Tighten the bolts to 15 ft. lbs. (21 Nm).

17.

18.

19. Connect the BARO sensor electrical connector.

20. Connect the main engine electrical harness connectors.

21. Push down on the latches (1) in order to connect the connectors.

22. Close the harness clip (2).

Fig. Main engine electrical harness connector

23. Position the A/C compressor.

24. Install the A/C compressor bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).

25. Connect the A/C cut out switch electrical connector.

26. Connect the A/C compressor clutch electrical connector.

27. Install the alternator.

28. Install the air intake pipe.

29. Prime the fuel system.

30. Start the engine. If the engine stalls, repeat the above step.

31. Once the engine starts, inspect for fuel leaks.

Prime the fuel system

Fuel System Purging

· BLEEDING

Bleeding

1. Prior to priming the engine, ensure that the following has been completed:

There is fuel in the fuel tank

The fuel filter has been installed and properly tightened

The fuel lines are properly connected

The fuel filter is cool to the touch

Any dirt or debris has been removed from the fuel filter head and vent valve

2. Turn the ignition key on for two minutes.

3. The fuel pump will be operating and starting the priming process. Do not start the engine during the first two minutes.

4. After completing the initial prime, turn the ignition off, then back to start and crank the engine for 15 seconds.

5. If the engine does not start, repeat the previous steps until the engine starts.

6. If the engine does not run after repeating the steps three times, turn the ignition key OFF for 60 seconds, allowing the Electronic Control Module (ECM) to reset.

7. Repeat the above steps until the engine starts.

8. If the engine runs, but does not run smoothly, increase the engine speed slightly by pressing the accelerator pedal. This will help to force out air through the system.

9. If the engine starts and runs but stalls again, turn the ignition key OFF for 60 seconds to reset the ECM and repeat the steps above.

10. Start the engine and allow it to idle for a few minutes.

11. Check the filter for leaks.

12. Check for fuel leaks and clear all Diagnostic Trouble Codes (DTCs).

1. Open the air bleed valve on the fuel manager/filter.

2. Connect a hose to the air bleed valve and place the other of the hose in a suitable container.

CAUTION

The Diesel/water mixture is flammable and may be hot. To avoid personal injury or property damage, do not allow the Diesel/water mixture to come in contact with skin, open flame or a hot engine. Do not overfill the container holding the fuel mixture as heat from a warm engine or any another heat source may cause the fuel to expand and leak from the container that may lead to a fire.

3. Remove the F/SOL fuse from the fuse panel.

4. Crank the engine in short intervals of 10-to-15 seconds until clear fuel is observed at the air bleed hose (wait for 1 minute between cranking intervals)

5. Remove the hose and close the air bleed valve.

6. Install the F/SOL fuse and start the vehicle. Allow the vehicle to run at idle for 5 minutes.

7. Check for fuel leaks, and clear any Diagnostic Trouble Codes (DTCs)