Replacing the fuel pressure regulator on an LLY Duramax engine can be a challenging task, but it is possible to do it yourself with the right tools and knowledge. The fuel pressure regulator is located in the valley of the engine, towards the front, and is attached to the CP3 pump. The most challenging part of the process is accessing the regulator due to its location and the number of components that need to be removed to reach it. It is important to have a good quality T25 Torx bit to remove the screws from the regulator, as well as a pipe wrench and a magnet to help with the bottom bolt. The whole process can take anywhere from 2 hours to a full day, depending on your level of experience and the ease of accessing the regulator. It is also important to clean the components and ensure no dirt falls into the CP3 pump during the replacement process.
What You'll Learn
Removing the EGR intake crossover
To remove the EGR intake crossover, you will first need to remove the turbo mouthpiece. Then, remove the intake downpipe with the two O-rings. Pull the fuel line up and out of the way, but you do not need to disconnect it. Plug the turbo inlet and intake inlet.
You will then need to clean the EGR intake crossover with a good cleaner, such as brake cleaner or electronics cleaner, and blow it dry. You should also clean the EGR bridge, especially if your EGR is not blocked, as it will be very dirty.
Next, carefully remove the EGR intake crossover. This is the part that goes from the CAC tube across the EGR and down to the intake in the valley. It is a challenging part to remove, so be prepared to spend some time on this step. Twist and pull the part, using a hammer if necessary, but be careful not to bind it if it is not straight.
Finally, put paper towels or newspaper around the engine valley to catch any falling tools or screws.
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Removing the turbo mouthpiece
To remove the turbo mouthpiece, you will need to first remove the EGR intake crossover. This is the part that goes from the CAC tube across the EGR and down to the intake in the valley. You will then need to remove the intake downpipe that has the two O-rings. Pull the fuel line that is in the way up and wire tie it out of the way—no disconnection is needed for this. Plug the turbo inlet and intake inlet.
You can then clean the FPR with any good cleaner, such as brake clean or electronics cleaner, and blow it dry. Put paper towels or newspaper around parts to keep tools and screws from falling into the abyss of the engine valley. Use a small piece of paper towel over the T25 bit to lock the screw to the bit during the installation of FPR screws.
Oil the O-rings and be careful what you use to pry the lower intake tube back on with. Service the turbo mouthpiece with a better part (AFE, LBZ) if it is the original or machine it out.
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Disconnecting the fuel line
Before beginning, gather the necessary tools, including a suitable Torx bit or screwdriver that fits the fuel pressure regulator screws. Some sources recommend a T25 Torx bit, while others suggest using a 3-inch or longer bit to reach the bottom bolt more easily. It is also advised to have a pipe wrench and a magnet on hand.
Now, let's get started:
- Prepare the workspace: Place paper towels or newspaper around the engine to catch any spills and prevent small parts from falling into the engine valley.
- Access the fuel line: To reach the fuel line, you will need to remove several components. These may include the EGR intake crossover, turbo "mouthpiece," intake downpipe, and possibly the AC compressor and alternator. Be careful when handling these parts and set them aside in a safe place.
- Locate the fuel line: Once you have removed the necessary components, you should be able to see the fuel line. It is connected to the fuel pressure regulator, which is located on the CP3 pump in the valley of the engine.
- Disconnect the fuel line: This step requires caution. Use the appropriate tool to loosen and remove the fuel line from the fuel pressure regulator. You may need to use the pipe wrench for extra leverage. Be aware that fuel may spill, so have a suitable container ready to catch any spills.
- Secure the fuel line: Once the fuel line is disconnected, use wire or zip ties to secure it out of the way. You don't want it to dangle and risk spilling fuel or getting damaged.
- Clean the area: Before proceeding, it is essential to clean the area around the fuel pressure regulator. Use a suitable cleaner, such as brake cleaner or electronics cleaner, and ensure the area is dry before moving on.
By following these steps, you will have successfully disconnected the fuel line, which is a crucial step in replacing the fuel pressure regulator on your LLY Duramax engine. Remember to stay organized, work carefully, and refer to vehicle-specific repair manuals or seek professional assistance if needed.
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Cleaning the FPR
To clean the FPR, you will need a good cleaner, such as brake cleaner or electronics cleaner. You will also need to blow dry the FPR after cleaning.
- Remove the EGR intake crossover. This is the part that goes from the CAC tube across the EGR and down to the intake in the valley.
- Remove the turbo 'mouthpiece'.
- Remove the intake downpipe with the two O-rings.
- Pull up the fuel line that is in the way and wire tie it out of the way. There is no need to disconnect it.
- Plug the turbo inlet and intake inlet.
- Clean the FPR with a suitable cleaner.
- Blow dry the FPR.
- Put paper towels or newspaper around the engine to catch any falling tools or screws.
- Use a small piece of paper towel over the T25 bit to lock the screw to the bit during the reinstallation of the FPR screws.
- Oil the O-rings before reinstalling any parts.
It is important to note that some people have found it difficult to access the FPR, especially the third screw. Moving the fuel line can make it more accessible. Additionally, using a longer T25 bit (around 2-3 inches) can help with accessing the screws.
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Removing the intake elbow
To remove the intake elbow, you will need to first remove the EGR intake crossover. This is the part that goes from the CAC tube across the EGR and down to the intake in the valley. You will also need to remove the turbo 'mouthpiece' and the intake downpipe that has the two O-rings. Pull the fuel line (which is in the way) up and wire it out of the way – there is no need to disconnect it.
Next, plug the turbo inlet and intake inlet. Clean the FPR with a good cleaner (brake cleaner or electronics cleaner) and blow dry. Put paper towels or newspaper around parts to keep tools and screws from falling into the abyss of the engine valley.
Finally, carefully remove the intake elbow.
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Frequently asked questions
It depends on your experience and the tools you have available. If it's your first time, it could take a full day, but if you're familiar with the process and have the right tools, it can be done in 3-4 hours.
A rough or surging idle, especially when the engine is cold, and a loss of power or sluggish performance.
You will need a good-quality Torx bit (T25) and a ratchet wrench. A long (3-inch) Torx bit can help with the hard-to-reach bottom bolt. Some people also recommend using a small piece of paper towel or tape over the Torx bit to keep the screw from falling.
You can buy them from online retailers like Amazon or specialist diesel parts suppliers like Oregon Fuel Injection. Prices range from around $90 to $125.
Some people recommend replacing the fuel filter and cleaning the MAF sensor at the same time. If your LLY Duramax has high mileage, you might also consider replacing the fuel pump and regulator with the LBZ version for improved performance.