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Home › Pontiac › 2001 › Aztek Base, AWD › Repair and Diagnosis › External Pages › Different car › Section 943 (Engine Controls - 6.6L (Lb7) (Introduction)) › Repair Instructions › Fuel Pressure Regulator Replacement › Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: 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.
    IMPORTANT: 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 (1).
    3. Fig 1: Fuel Pressure Regulator
    GM901301Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX®.

    Tighten: 

    • Tighten the screws a first pass to 4 N.m (35 lb in).
    • Tighten the screws a final pass to 7 N.m (62 lb in).

    4. Fig 2: Fuel Pressure Regulator Screws
    GM901300Courtesy of GENERAL MOTORS CORP.
  4. Install the injection pump inlet hose to the fuel feed distribution (leak) block.
    5. Fig 3: Injection Pump Inlet Hose At Fuel Feed Distribution Block
    GM901298Courtesy of GENERAL MOTORS CORP.
  5. Position the injection pump inlet clamp.
  6. Install the PCV hose to both valve covers.
    7. Fig 4: View Of Crankcase Ventilation Hoses At Valve Rocker Arm Covers
    GM687021Courtesy of GENERAL MOTORS CORP.
  7. Connect the oil level sensor harness electrical connector (1).
    8. Fig 5: Oil Level Electrical Connector
    GM788846Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel pressure regulator electrical connector (1).
    9. Fig 6: Fuel Pressure Regulator Electrical Connector
    GM786996Courtesy of GENERAL MOTORS CORP.
  9. Connect the left rear fuel injector electrical connector (1).
    10. Fig 7: Left Rear Fuel Injector Electrical Connector
    GM786988Courtesy of GENERAL MOTORS CORP.
  10. Connect the left front fuel injector electrical connector (1).
    11. Fig 8: Left Front Fuel Injector Electrical Connector
    GM786986Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel rail temperature sensor electrical connector (1).
    12. Fig 9: Fuel Rail Temperature Sensor Electrical Connector
    GM786977Courtesy of GENERAL MOTORS CORP.
  12. Connect the glow plug relay electrical connectors (1, 2, 3).
    13. Fig 10: Glow Plug Relay Electrical Connectors
    GM786978Courtesy of GENERAL MOTORS CORP.
  13. Connect the BARO sensor electrical connector (1)
    14. Fig 11: BARO Sensor Electrical Connector
    GM739503Courtesy of GENERAL MOTORS CORP.
  14. Connect the ECT sensor electrical connector (1).
    15. Fig 12: ECT Sensor Electrical Connector
    GM740506Courtesy of GENERAL MOTORS CORP.
  15. Install the main harnesses to the bracket.
  16. Install both main harness electrical connector to bracket bolts (1).

    Tighten:  Tighten the bolts to 21 N.m (15 lb ft).

    17. Fig 13: View Of Engine-To-Chassis Harness Connector & Bracket Bolts
    GM674680Courtesy of GENERAL MOTORS CORP.
  17. Connect both main harness electrical connectors.
    18. Fig 14: View Of Main Engine Harness Electrical Connectors
    GM674653Courtesy of GENERAL MOTORS CORP.
  18. Install the water outlet tube. Refer to Water Outlet Tube Replacement (6.6L (LB7) Engine) or Water Outlet Tube Replacement (6.6L (LLY) Engine) in Engine Cooling.
  19. Position the A/C compressor.
  20. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 53 N.m (37 lb ft).

    21. Fig 15: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  21. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 6.6L.
  22. Connect the A/C cut out switch electrical connector.
  23. Connect the A/C compressor clutch electrical connector.
  24. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
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