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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1339 (ENGINE CONTROLS AND FUEL - 3.6L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL PRESSURE SENSOR REPLACEMENT (LLT)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page is about a different car, the 2008 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With High Pressure Pump - LLT) .
  2. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement (DX) .
  3. Remove the intake manifold. Refer to Intake Manifold Replacement .
  4. Remove the foam insulator from the fuel rails.
    5. Fig 1: Removing/Installing Fuel Pressure Sensor From Fuel Injection Fuel Rail
    GM1977753Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel injector wiring harness electrical connector (1) from the fuel injection fuel rail fuel pressure sensor.
  6. Place a clean shop towel under the fuel injection fuel rail pressure sensor to fuel rail location.
    7. IMPORTANT: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.
  7. Using a 27 mm socket, remove the fuel pressure sensor (1) from the fuel injection fuel rail (2). Discard the fuel pressure sensor.
  8. Allow any fuel to drain from the fuel rail and pressure sensor location.
  9. Dry the sealing cone in the fuel rail and the area around the sensor joint with a lint free cloth.
  10. Inspect the sealing cone in the fuel rail. The surface should be free of fuel, debris, and burrs.
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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.