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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G3500, VAN CARGO, 4.8 VREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 2 (ENGINE CONTROL SYSTEM - 6.6L (LLY) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL PRESSURE REGULATOR REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G3500, Van Cargo, 4.8 V

Removal Procedure

2006 Chevrolet Chevy Express G3500, Van Cargo, 4.8 VSECTION Removal Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Remove the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Remove the air intake pipe.
  4. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement .
    5. Fig 2: Fuel Pressure Regulator Electrical Connector
    GM786996Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel pressure regulator electrical connector (1).
    6. Fig 3: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  6. Reposition the distribution block hose clamps.
  7. Remove the distribution block hoses from the distribution block.
    8. Fig 4: Fuel Pressure Regulator Screws
    GM901300Courtesy of GENERAL MOTORS CORP.
  8. 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.
  9. Using compressed air, thoroughly blow dry the regulator and pump.
  10. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX®.
    11. Fig 5: Fuel Pressure Regulator
    GM901301Courtesy of GENERAL MOTORS CORP.
  11. Remove the fuel pressure regulator (1).
  12. 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.