Fuel Pressure Regulator: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Remove fuel tank filler cap and release fuel tank pressure.
3. Perform fuel pressure release procedure. Service and Repair
4. Remove upper intake manifold.
5. Disconnect vacuum line at fuel pressure regulator.
6. Remove two retaining screws from fuel pressure regulator and discard.
7. Remove fuel pressure regulator, return seal and O-rings. Discard return seal and O-rings.

INSTALLATION
1. Lubricate new fuel pressure regulator O-rings with clean engine oil, X0-10W30-QSP or equivalent meeting Ford specification ESE-MC153-E.

CAUTION: Never use silicone grease. It will clog the fuel injectors.

2. Ensure sealing surfaces of fuel pressure regulator and fuel injection supply manifold are clean.
3. Install two new fuel pressure regulator O-rings onto the inlet tube of the fuel pressure regulator. Install a new return seal into the recess of the fuel injection supply manifold.
4. Slowly install the fuel pressure regulator into the recess in the fuel injection supply manifold, using caution to engage the fuel pressure regulator outlet tube into the fuel injection supply manifold without damaging the newly installed return seal.
5. Using two new retaining screws, install fuel pressure regulator on fuel injection supply manifold. Tighten retaining screws to 3.0-4.5 Nm (27-40 lb in).
6. Install vacuum line to the fuel pressure regulator.
7. Install upper intake manifold.
8. Install fuel tank filler cap.
9. Connect battery ground cable.

NOTE: Check all connections at fuel injection supply manifold and push on connection fittings to ensure proper engagement.

10. Turn ignition switch ON/OFF several times without starting engine to pressurize system. Check for fuel leaks.