FixVault
Home › Pontiac › 2002 › Aztek AWD › Repair and Diagnosis › External Pages › Different car › Section 917 (Engine Controls - 6.6L (LLY) (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.
    Fig 1: View Of Fuel Pressure Regulator
    GM901301Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage.
  1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.
  2. Install the fuel pressure regulator (1).
    3. Fig 2: Locating Fuel Pressure Regulator Screws
    GM901300Courtesy 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 3: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  4. Install the distribution block hoses to the distribution block.
  5. Position the distribution block hose clamps.
    6. Fig 4: View Of Oil Level Sensor Electrical Harness Connector
    GM1335526Courtesy of GENERAL MOTORS CORP.
  6. Connect the oil level sensor harness electrical connector.
    7. Fig 5: View Of Fuel Pressure Regulator Electrical Connector
    GM786996Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel pressure regulator electrical connector (1).
    8. Fig 6: View Of Fuel Temperature Sensor Electrical Connector
    GM1335528Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel temperature sensor electrical connector.
    9. Fig 7: View Of Engine Coolant Temperature Sensor And Electrical Connector
    GM1335413Courtesy of GENERAL MOTORS CORP.
  9. Install the water outlet tube. Refer toWater Outlet Tube Replacement (6.6L (LB7) Engine) or Water Outlet Tube Replacement (6.6L (LLY) Engine) in Engine Cooling.
  10. Connect the ECT sensor electrical connector.
    11. Fig 8: View Of Main Engine Electrical Harness Connector Bolts
    GM1334916Courtesy of GENERAL MOTORS CORP.
  11. Install the main connectors to the bracket.
  12. Install the main engine harness electrical connector bolts.

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

    13. Fig 9: View Of Barometric Pressure Sensor Electrical Connector
    GM1334921Courtesy of GENERAL MOTORS CORP.
  13. Connect the BARO sensor electrical connector.
    14. Fig 10: View Of Main Engine Electrical Harness Connector Latches & Harness Clip
    GM1409327Courtesy of GENERAL MOTORS CORP.
  14. Connect the main engine electrical harness connectors.
  15. Push down on the latches (1) in order to connect the connectors.
  16. Close the harness clip (2).
    17. Fig 11: View Of A/C Compressor & Bolts
    GM652573Courtesy of GENERAL MOTORS CORP.
  17. Position the A/C compressor.
  18. Install the A/C compressor bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

  19. Connect the A/C cut out switch electrical connector.
  20. Connect the A/C compressor clutch electrical connector.
  21. Install the generator. Refer to Generator Replacement (4.3L Engine) or Generator Replacement (4.8L, 5.3L, and 6.0L Engines) or Generator Replacement (6.6L (LB7) Engine) or Generator Replacement (6.6L (LLY) Engine) or Generator Replacement (8.1L Engine) in Engine Electrical.
  22. Install the air intake pipe. Refer to Air Intake Pipe Replacement .
  23. Prime the fuel system. Refer to Fuel System Priming .
  24. Start the engine. If the engine stalls, repeat the above step.
  25. Once the engine starts, inspect for fuel leaks.
About FixVault