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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 676 (ENGINE CONTROLS - 6.6L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL PRESSURE REGULATOR REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page is about a different car, the 2006 GMC Sierra, 2006 GMC Cab & Chassis Sierra, 2006 Chevrolet Silverado, and 2006 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .
  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.
    Fig 1: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  5. Remove the generator. Refer to Generator Replacement (4.8L, 5.3L, and 6.0L Engines) or Generator Replacement (6.6L (LLY) Engine) or Generator Replacement (8.1L Engine) .
  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 2: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  8. Open the harness clip (2).
  9. Remove the main engine electrical harness connectors.
    10. Fig 3: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  10. Remove the main engine harness electrical connector bolts.
  11. Remove the main connectors from the bracket.
    12. Fig 4: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
  13. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LLY) Engine) .
    14. Fig 5: View Of Fuel Temperature Sensor Electrical Connector
    GM1335528Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the fuel temperature sensor electrical connector.
    15. Fig 6: Disconnecting Fuel Pressure Regulator Electrical Connector
    GM786996Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the fuel pressure regulator electrical connector (1).
    16. Fig 7: View Of Oil Level Sensor Electrical Harness Connector
    GM1335526Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the oil level sensor harness electrical connector.
    17. Fig 8: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  17. Reposition the distribution block hose clamps.
  18. Remove the distribution block hoses from the distribution block.
  19. 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.
  20. Using compressed air, thoroughly blow dry the regulator and pump.
  21. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX®.
    Fig 9: Removing Fuel Pressure Regulator Screws
    GM901300Courtesy of GENERAL MOTORS CORP.
  22. Remove the fuel pressure regulator (1).
    Fig 10: Removing Fuel Pressure Regulator
    GM901301Courtesy of GENERAL MOTORS CORP.
  23. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:
    • Place a clean rag over the bore on order to collect the excess fuel.
    • Bump the engine over in order to flush any debris out of the regulator bore.
RENDER: 1.0x

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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.