Fuel Pressure Regulator: Service and Repair

FUEL PRESSURE REGULATOR REMOVAL



1. Disconnect negative terminal cable from battery.

CAUTION: Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

2. Drain engine coolant.

3. Remove throttle body.
(a) Disconnect the following hose, cables and connectors from the throttle body:



(1) Air hose
(2) Accelerator cable
(3) Cruise control actuator cable
(4) Throttle position sensor connector
(5) Sub-throttle position sensor connector
(6) Sub-throttle actuator connector




(b) Remove the 2 bolts and 2 nuts. and disconnect the throttle body from the air intake chamber.
(c) Remove the gasket.
(d) Disconnect the following hoses from the throttle body. and remove the throttle body:



(1) EVAP hose
(2) Water bypass hose (from No. 4 water bypass pipe)
(3) Water bypass hose (from cylinder head)
(4) P/S air hose




4. Disconnect vacuum sensing hose from fuel pressure regulator.

5. Disconnect fuel return pipe from fuel pressure regulator.
- Remove the union bolt and 2 gaskets. and disconnect the return pipe from the pressure regulator.

CAUTION: GASOLINE WILL SPRAY OUT UNDER PRESSURE.
- Put a shop rag under the pressure regulator.
- Slowly loosen the union bolt.

6. Remove fuel pressure regulator.



(a) Remove the 2 bolts. and pull out the pressure regulator.
(b) Remove the 0-ring from the pressure regulator.




FUEL PRESSURE REGULATOR INSTALLATION
1. Install fuel pressure regulator.



(a) Apply a light coat of gasoline to a new 0-ring, and install it to the pressure regulator.



(b) Attach the pressure regulator to the delivery pipe.
(c) Check that the pressure regulator rotates smoothly.
NOTICE: If it does not rotate smoothly, the 0-ring may be pinched, so remove the pressure regulator and perform again steps (b) and (c) above.



(d) Install the pressure regulator with the 2 bolts.
Torque: 8.8 Nm (78 in.lb)

2. Connect fuel return pipe to fuel pressure regulator.
- Install the return pipe with 2 new gaskets and the union bolt.
Torque: 27 Nm (20 ft.lb)




3. Connect vacuum sensing hose to fuel pressure regulator.

4. Install throttle body.
(a) Connect the following hoses to the throttle body:



(1) EVAP hose
(2) Water bypass hose (from No. 4 water bypass pipe)
(3) Water bypass hose (from cylinder head)
(4) P/S air hose
(b) Install a new gasket to the air intake chamber.



(c) Install the throttle body with the 2 bolts and 2 nuts.
Torque: 21 Nm (15 ft.lb)
(d) Connect the following hose, cables and connectors to the throttle body:



(1) Air hose
(2) accelerator cable
(3) Cruise control actuator cable
(4) Throttle position sensor connector
(5) Sub-throttle position sensor connector
(6) Sub-throttle actuator connector

5. Fill with engine coolant.
6. Connect negative terminal cable to battery.
7. Check for fuel leaks. (Refer to "Checking the Fuel System For Leaks" at System level under Service and Repair)
Checking the Fuel System For Leaks