Fuel Pressure Regulator: Service and Repair

NOTE: Fuel system pressure must be released prior to any service of fuel injection components.

NOTE: Tag injector electrical connectors for proper cylinder identification.

NOTE: Intake manifold plenum must be removed before fuel injectors can be replaced.

REMOVAL
1. Remove intake manifold plenum
2. Disconnect the negative battery cable
3. Disconnect fuel supply and return tubes from fuel rail. Use shop towels to soak up any fuel that was spilled.
4. Remove injector electrical connectors.
5. Remove fuel pressure regulator vacuum tube.

Fuel Injector Clamp:

6. Remove fuel rail mounting bolts.

Fuel Injector Clamp:

7. Remove injector clamp screw.

Fuel Injector Clamp Removal/Installation:

8. Slide injector clamp toward rear of engine, and remove.
9. Install fuel rail mounting bolts finger tight.

Fuel Pressure Regulator Removal 3.5L:

10. Using thin flat blade screwdriver, pry fuel pressure regulator out of fuel rail.
11. Ensure the O-rings were removed with the regulator. If not, remove them from fuel rail.

INSTALLATION

NOTE: If fuel rail was removed to service regulator, use a new gasket when installing fuel rail.

1. Before installing regulator lubricate the O-rings with a drop of clean engine oil.
2. Install regulator flush with fuel rail.
3. Remove fuel rail mounting bolts.
4. Install fuel injector clamps.
5. Install fuel rail mounting bolts and torque to 100 in-lbs (11 Nm).
6. Install fuel injector clamp screw.
7. Install fuel injector electrical connectors
8. Install fuel pressure regulator vacuum tube.
9. Connect fuel supply and return tubes from fuel rail. Use shop towels to soak up any fuel that was spilled.
10. Install intake manifold plenum.
11. Connect the negative battery cable.
12. Connect the DRB II scan tool and select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. SEE COMPUTERS AND CONTROL SYSTEMS/SCAN TOOL ORIENTATION

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test.