Astro, Safari 1997-2005

Fuel Pressure Regulator

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section.
  4.  
  5. Remove the upper manifold assembly.
  6.  
  7. Remove the fuel pressure regulator vacuum tube.
  8.  
  9. Disassemble the fuel pressure regulator snapring retainer.
  10.  
  11. Remove the fuel pressure regulator assembly and the O-rings. Discard the O-rings, filter and back-up O-rings.

    Click image to see an enlarged view

    Fig. The fuel pressure regulator is retained by this clip



    Click image to see an enlarged view

    Fig. Replace the O-rings whenever the fuel pressure regulator is removed

  12.  

To install:

  1. Lubricate the O-rings with clean engine oil and install as an assembly.
  2.  
  3. Install the fuel pressure regulator, attach the vacuum tube.
  4.  
  5. Install the snapring retainer.
  6.  
  7. Install the upper manifold assembly.
  8.  
  9. Connect the negative battery cable.
  10.  

  1. Relieve the fuel system pressure.
  2.  
  3. Remove the upper intake manifold assembly.
  4.  
  5. Remove the fuel pressure regulator retainer clip (5).
  6.  
  7. Pull and twist the fuel pressure regulator (6) in order to remove the fuel pressure regulator from the fuel pressure regulator housing using a shop towel to catch any spilled fuel.
  8.  
  9. Remove the regulator seal lower O-ring (3).
  10.  
  11. Remove the regulator assembly filter (2).
  12.  
  13. Remove the regulator seal upper O-ring (1).
  14.  
  15. Remove the regulator seal backup ring (7).
  16.  
  17. Discard the O-rings.

    Click image to see an enlarged view

    Fig. Exploded view of throttle body assembly

  18.  

To install:


NOTE
If the fuel pressure regulator is to be reinstalled, inspect the filter screen for contamination. If the filter screen is contaminated, replace the regulator.

  1. Lubricate the new O-rings with clean engine oil.
  2.  
  3. Install the regulator seal backup ring (7).
  4.  
  5. Install the regulator seal upper O-ring (1).
  6.  
  7. Install the regulator assembly filter (2).
  8.  
  9. Install the regulator seal lower O-ring (3).
  10.  
  11. Assemble the regulator (6) with the vacuum tube pointing down into the regulator retainer clip.
  12.  
  13. Install the fuel pressure regulator retainer clip (5).
  14.  
  15. Install the upper manifold assembly.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Inspect for leaks.
    1. Turn the ignition ON , with the engine OFF , for 2  seconds.
    2.  
    3. Turn the ignition OFF for 10 seconds.
    4.  
    5. Turn the ignition ON , with the engine OFF .
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  
  21. Install the engine cover.
  22.  

 
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