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Removal & Installation

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the air intake pipe. Disconnect the Air Conditioning (A/C) compressor clutch electrical connector. Disconnect the A/C cut out switch electrical connector. Remove the drive belt. Remove the A/C compressor bolts. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
  2. Remove the water outlet tube. Disconnect both main harness electrical connectors. Remove both main harness electrical connector to bracket bolts. Remove the main harnesses from the bracket. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
  3. Disconnect the Barometric (BARO) pressure sensor electrical connector. Disconnect the glow plug relay electrical connectors. Disconnect the fuel rail temperature sensor electrical connector. Disconnect the left front fuel injector electrical connector. Disconnect the left rear fuel injector electrical connector. Disconnect the fuel pressure regulator electrical connector.
  4. Disconnect the oil level sensor harness electrical connector. Remove the Positive Crankcase Ventilation (PCV) hose from both valve covers. Reposition the injection pump inlet clamp. Remove the injection pump inlet hose from the fuel feed distribution (leak-off) block. Reposition the hose.
  5. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981, or equivalent. Using compressed air, thoroughly blow dry the regulator and pump. Remove the 3 fuel pressure regulator screws using a T25 TORX®. Remove the fuel pressure regulator. See Fig 1.
    6. NOTE: DO NOT use compressed air to remove debris while the fuel pressure regulator is removed.
  6. 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 pump bore in order to collect the excess fuel.
    • Bump the engine over in order to flush any debris out of the regulator bore.
  7. If the pressure regulator is being re-used, check the "O" rings for damage. If the "O" rings are damaged, install NEW "O" rings. Lubricate and install NEW "O" rings onto the regulator. Lubricate the "O" rings with clean, NEW engine oil. If the regulator is installed at an angle the "O" rings may be damaged, resulting in possible fuel leakage. To install, reverse removal procedure.
Fig 1: Locating Fuel Pressure Regulator
G00079451Courtesy of GENERAL MOTORS CORP.
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