Fuel Pressure Regulator: Service and Repair

FUEL PRESSURE REGULATOR REPLACEMENT

REMOVAL PROCEDURE




1. Remove the engine cover.
2. Remove the air outlet duct.
3. Remove the air intake pipe.
4. Remove the thermostat housing crossover.




5. Disconnect the fuel pressure regulator electrical connector (1).




6. Reposition the distribution block hose clamps.
7. Remove the distribution block hoses from the distribution block.




8. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent.
9. Using compressed air, thoroughly blow dry the regulator and pump.
10. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX(R).




11. Remove the fuel pressure regulator (1).
12. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following:
- Place a clean rag over the bore on order to collect the excess fuel.
- Bump the engine over in order to flush any debris out of the regulator bore.

INSTALLATION PROCEDURE

IMPORTANT: If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings.




1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil.

IMPORTANT: If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage.

2. Install the fuel pressure regulator (1).




3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX(R).
- Tighten the screws a first pass to 4 N.m (35 lb in).
- Tighten the screws a final pass to 7 N.m (62 lb in).

NOTE: Refer to Fastener Notice.




4. Install the distribution block hoses to the distribution block.
5. Position the distribution block hose clamps.




6. Connect the fuel pressure regulator electrical connector (1).
7. Install the thermostat housing crossover.
8. Install the air outlet duct.




9. Install the air intake pipe.
10. Prime the fuel system. Refer to Fuel System Priming.
11. Start the engine. If the engine stalls, repeat the above step.
12. Once the engine starts, inspect for fuel leaks.
13. Install the engine cover.