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    Pacifica, 2003-2005

    Fuel Pressure Regulator

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    Removal & Installation




    NOTE
    The fuel pressure regulator is on the passenger side of the fuel tank.

    1. Release the fuel pressure, refer to the Fuel Pressure Release Procedure in this section.
      2.  
    2. Disconnect the negative battery cable.
      3.  
    3. Remove fuel tank, as follows:
      1. Drain fuel tank dry into holding tank or a properly labeled GASOLINE safety container.
        2.  
      2. Raise vehicle and support.
        3.  
      3. Disconnect the exhaust system between the catalytic converter and the muffler.
        4.  
      4. Support the exhaust system with jack stands.
        5.  
      5. Remove muffler hanger rubber grommets.
        6.  
      6. Remove the center exhaust hanger rubber grommets.
        7.  
      7. Remove the rear portion of the exhaust system and set on floor.
        8.  
      8. Disconnect the fuel tank electrical connector.
        9.  
      9. Disconnect the fuel line and EVAP line.
        10.  
      10. Disconnect the vapor recirculation tube.
        11.  
      11. Mark the driveshaft rear connection.
        12.  
      12. Disconnect the driveshaft rear connection.
        13.  
      13. Remove the driveshaft support/bearing.
        14.  
      14. Support driveshaft on jack.
        15.  
      15. Remove the left rear tire and splash shield.
        16.  
      16. Remove the fuel filler tube from the rubber hose at fuel tank.
        17.  
      17. Support the fuel tank with a transmission jack.
        18.  
      18. Remove the 2 fuel tank straps.
        19.  
      19. Lower fuel tank
        20.  
      20. Drain Fuel Tank, use an approved GASOLINE draining station.
        21.  
      21. Remove tank from vehicle.
        NOTE
        Clean the area before removing module lockring.

        22.  

      4.  
    4. Disconnect lines from top of the module.
      5.  
    5. Remove module lockring.
      NOTE
      Use a brass punch to remove the 1/4 turn lockring.



      Click image to see an enlarged view

      Fig. Location of the locking ring contact points

      Location of the locking ring contact points
      6.  
    6. Drain fuel tank, use an approved gasoline draining station.
      7.  
    7. Remove module from fuel tank.
      8.  
    8. Remove wire from side of regulator, then depress the tab on the connector in order to remove the ground wire.

      Click image to see an enlarged view

      Fig. Remove wire from side of regulator, and depress the tab on the connector in order to remove the ground wire

      Remove wire from side of regulator, and depress the tab on the connector in order to remove the ground wire
      9.  
    9. Use a socket to compress the 4 tabs that retain regulator.
      10.  
    10. Pry up regulator and remove regulator and O-rings.
      NOTE
      The O-rings should be placed on the regulator first, to prevent them from being rolled out of position during regulator install.

      11.  

    To install:

    1. Lightly lubricate the O-rings with clean engine oil and place them onto regulator.
      2.  
    2. Push regulator down and into place.
      3.  
    3. Install ground wire.
      4.  
    4. Install module and gasket seal. Ensure seal is properly positioned in fuel tank groove.
      5.  
    5. Install the module lockring.
      NOTE
      Use a brass punch to Install the 1/4 turn lockring. Make sure all 5 tabs are properly seated.

      6.  
    6. Connect fuel line and vapor lines.
      7.  
    7. Install fuel tank, as follows:
      1. Support the fuel tank with a transmission jack.
        2.  
      2. Raise fuel tank and install to vehicle.
        3.  
      3. Install the 2 fuel tank straps.
        4.  
      4. Install the fuel filler tube to the rubber hose at fuel tank.
        5.  
      5. Connect the vapor recirculation tube.
        6.  
      6. Connect the fuel line and EVAP line.
        7.  
      7. Connect the fuel tank electrical connector.
        8.  
      8. Support driveshaft on jack.
        9.  
      9. Install the driveshaft support/bearing.
        10.  
      10. Align the marks on the driveshaft to the rear connection.
        11.  
      11. Connect the driveshaft rear connection.
        12.  
      12. Install the exhaust system and tighten clamp.
        13.  
      13. Install the center exhaust hanger rubber grommets.
        14.  
      14. Install muffler hanger rubber grommets.
        15.  
      15. Install the left rear tire.
        16.  
      16. Lower vehicle.
        17.  

      8.  
    8. Connect the negative battery cable.
      9.  
    9. Fill fuel tank. Use the DRBIII® scan tool to pressurize the fuel system. Check for leaks
      10.  

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