Fuel Pressure Regulator: Service and Repair

REMOVAL

1. Release pressure from fuel system at fuel presure relief valve (Schrader) on fuel rail assembly.
2. Remove vacuum line at pressure regulator.
3. Remove two retaining screws from regulator housing.
4. Remove pressure regulator assembly o-ring and washer. Discard washer and inspect o-ring for signs of cracks or deterioration.
5. Inspect fuel return tube for kinks and abrasions.

Fuel Pressure Regulator:

INSTALLATION

1. Lubricate fuel pressure regulator o-ring with light oil.
NOTE: Never use silicone grease. It will clog the injectors.
2. Ensure surfaces of fuel pressure regulator and fuel injection manifold are clean.
3. Install new washer and o-ring on regulator.
4. Install fuel pressure regulator on injector manifold. Refer to SPECIFICATIONS.
5. Install vacuum line to regulator.
6. Connect fuel supply and return line couplings as follows:
a. Ensure that garter spring is in cage of male fitting. If garter spring is missing, install a new spring by pushing it into cage opening. If garter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring.
b. Clean all dirt or foreign material from both pieces of coupling.
WARNING: Use only the specified o-rings as they are made of a special material. The use of any o-ring other than the specified o-ring may allow the connection to leak intermittently during vehicle operation.
c. Lubricate male fittings and o-rings and inside of female fitting with clean engine oil.
d. Install plastic indicator ring into cage opening if indicator ring is to be used.
e. Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting. If plastic indicator ring is used, it will snap out of cage opening when coupling is connected to indicate engagement.
f. If indicator ring is not used, ensure coupling engagement by visually checking to be sure garter spring is over flared end of female fitting.
7. Push connect fuel supply line (1/2 inch) and fuel return line (3/8 inch) to fuel rail.
8. Install fuel line safety clips.
9. Install the fuel filer clip.
10. Connect battery ground cable.
11. Turn ignition on and off several times without starting engine to pressurize the fuel system. Check for fuel leaks at pressure regulator, fuel injectors and fuel connect fittings.
12. Start engine and warm to operating temperature. Check for coolant leakage if coolant was removed.