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Fuel Pressure Regulator: Service and Repair

Figure 4C-8 Upper And Lower Intake Components:




Legend:
1. Manifold Assembly - Upper
2. Stud - Upper Inlet Manifold
3. Harness Assembly - EGR Valve and Fuel Pressure Regulator Vacuum
4. Seal - MAP sensor
5. Sensor- Manifold Absolute Pressure (MAP)
6. Bolt - MAP Sensor Attaching
7. Fitting and Washer Assembly - EGR Transfer Tube
8. Valve Assembly - Idle Air Control (IAC)
9. Screw - AC Valve Attaching
10. 0-Ring - IAC Valve
11. Tube Assembly - EGR transport
12. Bolt - Upper Inlet Manifold
13. Gasket - Upper Inlet Manifold
14. Fitting - Power Brake
15. 0-Ring - Fuel Inject or Upper
16. Injector Assembly - (Bottom Feed) SFI Fuel injectors
17. 0-Ring - Fuel Injector Lower
18. Screw - Fuel Pressure Connection Fitting
19. Bracket - Fuel Pressure Connection Fitting
20. Fitting - Fuel Feed
21. 0-Ring - Fuel Feed Pipe Fitting
22. 0-Ring - Fuel Feed Pipe Fitting
23. Pipe Assembly - Fuel Feed
24. Manifold Assembly - Lower
25. Retainer - Injectors
26. Screw - Injectors Retainer Attaching
27. Screw - TP Sensor Attaching
28. Sensor - Throttle Position (TP)
29. Pipe Assembly - Fuel Return
30. 0-Ring - Fuel Return Pipe Fitting
31. Screen - Filter (if so equipped)
32. 0-Ring - Fuel Pressure Regulator
33. Screw - Fuel Pressure Regulator Attaching
34. Regulator Assembly - Fuel Pressure

REMOVE OR DISCONNECT
1. Relieve fuel system pressure.
2. Disconnect negative battery cable.
3. Remove vacuum hose from regulator.
4. Fuel return pipe clamp.
5. Fuel return pipe and 0-ring from regulator - Discard 0-ring.
6. Pressure regulator bracket attaching screw.
7. Pressure regulator assembly and 0-ring - Discard 0-ring.

INSPECT
If fuel pressure regulator is to be reinstalled, inspect filter screen (if equipped) for contamination. If contaminated replace filter screen.

INSTALL OR CONNECT
1. Lubricate new pressure regulator 0-ring with clean engine oil, then install on pressure regulator.
2. Pressure regulator assembly onto manifold.
3. Pressure regulator bracket attaching screw coated with appropriate thread-locking material.

Tighten Pressure regulator bracket attaching screw to 3.5 Nm (31 in. lbs.).

4. Vacuum hose to regulator.
5. Lubricate new fuel return pipe 0-ring with clean engine oil, then install on end of pipe.
6. Fuel return pipe to pressure regulator.

Tighten Fuel return pipe attaching nut 30 Nm (22 in. lbs.).

7. Fuel return pipe clamp attaching nut to lower manifold assembly.
8. Tighten fuel filler cap.
9. Negative battery terminal.

INSPECT
Turn ignition switch to the "ON" position for two seconds, then turn to the "0FF" position for ten seconds. Again turn to the "ON" position and ch4eck for fuel leaks.

IMPORTANT: The hardware used to attach the upper manifold Throttle Position (TP) sensor, Idle Air Control (IAC) valve, MAP sensor, power brake fitting, and the lower manifold pressure regulator and injector bracket attaching hardware are coated with thread-locking adhesive. If any these parts are removed for service, inspect the attaching screw threads. There should be enough thread-locking material (adhesive or compound) on the threads to ensure proper relocking. If not, clean the threads and apply a thread locking adhesive to the threads before reassembly. Replacement screws are included in the service screw assortment package. New attaching hardware is included in the service packages.

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