Fuel Pressure Regulator: Service and Repair

Fuel Rail Assembly, Exploded View:

Intake Plenum And Runners:

Fuel Rail Removal And Installation:

WARNING: To reduce the hazard of fire and personal injury that may result from a fuel leak, always replace any O-ring seal exposed during component service.

NOTE: The fuel pressure regulator and base are serviced as a complete assembly only. DO NOT attempt to remove the regulator cover.


REMOVAL:
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, see MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Remove the intake plenum and runners, see INTAKE PLENUM AND RUNNERS.
4. Remove the fuel rail assembly, see FUEL RAIL ASSEMBLY.
5. Remove the rear crossover retainer to regulator base attaching screw and retainer.
6. Remove the rear crossover tube and O-ring from the regulator base, discard the O-ring.
7. Remove the pressure regulator bracket screws and bracket.
8. Remove the pressure regulator base to rail screw.
9. Remove the pressure regulator and base assembly:

^ Separate the regulator base from the fuel rail, then disconnect it from the fuel outlet tube.

10. Remove the fuel outlet O-ring, and discard.
11. Remove the base to rail connector.
12. Remove the O-rings from the base to rail connector, and discard.


INSTALLATION:
1. Lubricate new base to connector O-rings with clean engine oil, and install.
2. Insert the base to rail connector into the regulator base.
3. Lubricate a new outlet tube O-ring and install it on the end of the outlet tube.
4. Assemble the pressure regulator and base assembly.

^ Connect the regulator base to the fuel outlet tube, then to the fuel rail.

5. Install the base to rail screw, finger tighten only.
6. Assemble the pressure regulator bracket with the attaching screws, finger tighten only.
7. Lubricate a new rear crossover tube O-ring and install it on the end of the tube.
8. Assemble the rear crossover tube to the regulator base.
9. Attach the crossover tube retainer with the attaching screw, finger tighten only.
10. Tighten all attaching screws to 5.0 N-m (44 lb.in).
11. Install the fuel rail assembly.
12. Check for fuel leaks:

a. Temporarily connect the negative battery cable.
b. With the engine OFF and the ignition ON, check for fuel leaks.
c. Disconnect the negative battery cable.

13. Install the intake plenum and runners.
14. Connect the negative battery cable.