Fuel Pressure Regulator: Service and Repair

PRESSURE REGULATOR REPLACEMENT

Fuel Rail Service Port:

Release of Fuel System Pressure
^ Drain fuel system pressure. See: SYSTEM DIAGNOSIS / DRAINAGE OF FUEL SYSTEM.

Removal





^ Remove:
- Upper charge-air pipe.
- Fuel rail cover.
- Injector connectors.
- Fuel line clips.

^ Install injector clamps P/N 9995533.





^ Remove / Disconnect:
- Vacuum hose from pressure regulator.
- Fuel rail retaining bolts.
- Lift off fuel rail complete with injectors.

NOTE: Handle injectors carefully to avoid damage to injection nozzles and needles.

NOTE: Recover all rubber damping elements mounted on intake manifold.





^ Remove:
- Pressure regulator mounting screws (two). Place rag under regulator to soak up fuel spillage.
- Regulator.

^ Install:
- New pressure regulator.
- Regulator mounting screws. Tighten screws.
- All rubber mounting elements on intake manifold.
^ Lubricate injector 0-rings with petroleum jelly.

Installation





^ Install/reconnect:
- All rubber damping elements on intake manifold.
- Fuel rail on intake manifold.
- Fuel rail retaining bolts.
- Fuel line clips.

Use new bolts and tighten to 10 Nm (7.5 ft lb).

^ Remove injector clamps.
^ Injector connectors. Check that each connector is fitted with Rubber seal.
^ Covers over fuel rail and throttle pulley.
^ Upper charge-air pipe.