GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Express - AWD 🢒 Engine 🢒 Engine Controls and Fuel - 6.6L 🢒 Fuel Pressure Regulator Replacement

Removal Procedure

    Object Number: 786996 Size: SH
  1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement.
  2. Disconnect the fuel pressure regulator electrical connector (1).
  3. Reposition the distribution block hose clamps.
  4. Remove the distribution block hoses from the distribution block.

    5. Object Number: 901300 Size: SH
  5. 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.
  6. Using compressed air, thoroughly blow dry the regulator and pump.
  7. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX®.

    8. Object Number: 901301 Size: SH
  8. Remove the fuel pressure regulator (1).
  9. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:
    10. • 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.

Installation Procedure

Note: If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.


    Object Number: 901301 Size: SH
  1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.

    2. Note: 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. Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 901300 Size: SH
  3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX®.
    4. • 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. Install the distribution block hoses to the distribution block.
  5. Position the distribution block hose clamps.

    6. Object Number: 786996 Size: SH
  6. Connect the fuel pressure regulator electrical connector (1).
  7. Install the air outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  8. Install the center intake manifold. Refer to Center Intake Manifold Replacement.
  9. Prime the fuel system. Refer to Fuel System Priming.
  10. Start the engine.

    11. If the engine stalls, repeat the above step.

  11. Once the engine starts, inspect for fuel leaks.