Fuel Pressure Regulator: Service and Repair

FUEL PRESSURE REGULATOR REPLACEMENT

REMOVAL PROCEDURE




1. Remove the air intake pipe.
2. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
3. Disconnect the A/C cut out switch electrical connector.
4. Remove the A/C compressor bolts.
5. Remove the generator.
6. Reposition the A/C compressor (with the hoses attached) to the right side of the engine compartment.




7. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
8. Open the harness clip (2).
9. Remove the main engine electrical harness connectors.




10. Remove the main engine harness electrical connector bolts.
11. Remove the main connectors from the bracket.




12. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
13. Remove the water outlet tube.




14. Disconnect the fuel temperature sensor electrical connector.




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




16. Disconnect the oil level sensor harness electrical connector.




17. Reposition the distribution block hose clamps.
18. Remove the distribution block hoses from the distribution block.




19. 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.
20. Using compressed air, thoroughly blow dry the regulator and pump.
21. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX(R).




22. Remove the fuel pressure regulator (1).
23. 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 oil level sensor harness electrical connector.




7. Connect the fuel pressure regulator electrical connector (1).




8. Connect the fuel temperature sensor electrical connector.




9. Install the water outlet tube.
10. Connect the ECT sensor electrical connector.




11. Install the main connectors to the bracket.
12. Install the main engine harness electrical connector bolts.

Tighten the bolts to 21 N.m (15 lb ft).




13. Connect the main engine electrical harness connectors.
14. Push down on the latches (1) in order to connect the connectors.
15. Close the harness clip (2).




16. Position the A/C compressor.
17. Install the A/C compressor bolts.

Tighten the bolts to 50 N.m (37 lb ft).

18. Connect the A/C cut out switch electrical connector.
19. Connect the A/C compressor clutch electrical connector.
20. Install the generator.
21. Install the air intake pipe.
22. Prime the fuel system. Refer to Fuel System Priming.
23. Start the engine. If the engine stalls, repeat the above step.
24. Once the engine starts, inspect for fuel leaks.