Showing posts with label regulator. Show all posts
Showing posts with label regulator. Show all posts

Saturday, November 9, 2013

How to Replace the Fuel Pressure Regulator on a Duramax LLY

Duramax engines are eight-cylinder, 6.6-liter engines manufactured by General Motors. The LLY version was in production from 2004 to 2005, and is a common engine for full-size Chevrolet pickups. The fuel system for the Duramax LLY engine is highly-pressurized, and requires a regulator to maintain the correct pressure. The replacement procedure for the fuel pressure regulator is the same for all vehicles with a Duramax LLY engine.

Instructions

    1

    Disconnect the air intake pipe and alternator with a socket wrench. Detach the electrical connectors for the air conditioning clutch and air conditioning cut-out switch. Remove the mounting bolts for the air conditioning compressor, and push the compressor to the right of the engine.

    2

    Lift up the latches on the connectors for the main wiring harness on the engine, and release the clip on the harness to detach the connectors. Disconnect the connector from the barometric pressure sensor. Remove the mounting bolts on the bracket for the engine wiring harness with a socket wrench, and disconnect the bracket.

    3

    Disconnect the electrical connectors from the engine coolant temperature sensor, fuel temperature sensor, oil level sensor and fuel pressure regulator. Detach the water outlet tube from the engine. Release the clamps for the distribution block hoses, and disconnect the hoses. Disconnect the retaining bolts for the Exhaust Gas Recirculation (EGR) hose, and release the clamp on the hose so you can push it aside.

    4

    Clean the fuel pressure regulator and injection pump with solvent 12377981 and compressed air. Disconnect the screws on the fuel pressure regulator with a T25 TORX tool, and detach the fuel pressure regulator.

    5

    Coat the new O-rings for the fuel pressure regulator with clean engine oil, and mount them to the new fuel pressure regulator. Install the new fuel pressure regulator, and tighten its screws to 35 inch-pounds, with a T25 TORX tool. Tighten the screws for the fuel pressure regulator again to 62 inch-pounds.

    6

    Install the remaining components by performing steps 1 through 3 in reverse order. Tighten the mounting bolts for the EGR hose and the main engine wiring harness to 15 foot-pounds with a torque wrench. Tighten the bolts for the air conditioning compressor to 37 foot-pounds.

    7

    Crank the engine until it starts to prime the fuel system. Allow the engine to idle and check for fuel leaks.

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Thursday, November 7, 2013

How to Install a 1995 Neon Fuel Pressure Regulator

The Neon is a compact car that Chrysler manufactured under its Dodge brand from 1995 to 2005. The 1995 model had a 4-cylinder, 2.0-liter engine with fuel injection, which requires a highly pressurized fuel system. This requires a fuel pressure regulator to maintain the pressure in the fuel system within a specific range. The fuel pressure regulator in a 1995 Dodge Neon is part of the fuel pump module, which you must remove to install the fuel pressure regulator.

Instructions

    1

    Remove the negative cable from the battery. Open the fuel filler cap and remove the cap for the fuel pressure port on the fuel rail. Place one end of hose C-4799-2 in a gasoline container, and attach the other end of the hose to the fuel pressure port. Allow the fuel to drain into the gasoline container. Disconnect the hose from the fuel pressure port and replace the cap on the port.

    2

    Raise the Neon with a jack and support it on jack stands. Remove the cap from the drain tube at the rear of the fuel tank. Connect one end of a siphon hose to the drain tube and place the other end into a gasoline container. Drain the fuel tank into the gasoline container. Replace the cap on the drain tube.

    3

    Press the quick-connect fittings on the fuel lines to the fuel pump module and detach the fuel lines. Tap the locking ring for the fuel pump module with a hammer and brass punch to turn the locking ring counterclockwise. Remove the locking ring and pull the fuel pump module from the fuel tank. Discard the O-rings for the fuel pump module.

    4

    Pull apart the tabs on the retainer for the pressure regulator. Pry the fuel pressure regulator from its housing with a small pry tool. Lubricate the new O-rings with engine oil and place them onto the fuel pump module. Push the new fuel pressure regulator into position on the pump module. Push the tabs on the retainer for the fuel pressure regulator over the corresponding tabs on the fuel pump module.

    5

    Install the fuel pump module into the fuel tank and place the locking ring into position on the fuel pump module. Turn the locking ring clockwise until it locks into place. Connect to the fuel lines to the fuel pump module.

    6

    Lower the vehicle and fill the tank with fuel. Fasten the filler cap for the fuel tank and connect the cable to the negative battery terminal with a socket wrench.

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