Fuel Pressure Regulator

GM Cavalier/Sunfire 1995-2000 Repair Guide

REMOVAL&INSTALLATION
REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4 and 5

Fig. 1: Cross-section view of the fuel

pressure regulator assembly

Fig. 2: Use a wrench to unfasten the fuel

line-to-regulator fitting

Fig. 3: Disconnect the vacuum hose from the

regulator

Fig. 4: Remove the pressure regulator

attaching screw

Fig. 5: Remove the regulator from the

manifold and discard the O-ring

1.
2.
3.
4.
5.

Relieve the fuel system pressure as outlined earlier.

Disconnect the negative battery cable.
Remove the vacuum hose from the regulator.
Place a rag under the connection and remove the fuel return pipe clamp.
Remove the fuel return pipe and O-ring from the regulator. Discard the Oring.
6. Unfasten the pressure regulator bracket attaching screw, then remove the
pressure regulator assembly and O-ring. Discard the O-ring.
To install:
7. Lubricate a new pressure regulator O-ring with clean engine oil, then install
on the pressure regulator.

8. Install the pressure regulator assembly onto the manifold.

9. Install the pressure regulator bracket attaching screw coated with the
appropriate thread locking material and tighten to 31 inch lbs. (3.5 Nm).
10. Connect the vacuum hose to the regulator.
11. Lubricate a new fuel return pipe O-ring with clean engine oil, then install on
the end of the pipe.
12. Install the fuel return pipe to the pressure regulator and tighten the attaching
nut to 22 inch lbs. (30 Nm).
13. Fasten the fuel return pipe clamp attaching nut to the lower manifold
assembly.
14. Tighten the fuel filler cap.
15. Connect the negative battery cable and turn the ignition ON for 2 seconds,
OFF for 10 seconds, then ON and check for fuel leaks.