Cavalier, Sunfire 2001-2005

Fuel Pressure Regulator

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Removal & Installation



2.2L (VIN 4) Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner outlet resonator.
  4.  
  5. Remove the air cleaner resonator bracket.
  6.  
  7. Disconnect the vacuum hose from the fuel pressure regulator.
  8.  
  9. Disconnect the fuel return pipe from the fuel pressure regulator.
  10.  
  11. Remove the pressure regulator attaching screw.
    NOTE
    If the fuel pressure regulator is to be reinstalled, inspect the filter screen for contamination. If contamination is found, remove and discard the filter screen.

  12.  
  13. Remove the pressure regulator assembly and the O-ring. Discard the O-ring.
  14.  

To install:

  1. Lubricate the new pressure regulator O-ring with clean engine oil.
  2.  
  3. Install the O-ring on the pressure regulator.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Install the pressure regulator attaching screw coated with the appropriate thread-locking material and tighten the pressure regulator attaching screw to 84 lb inches (9.5 Nm).

  4.  
  5. Connect the vacuum hose to the fuel pressure regulator.
  6.  
  7. Connect the fuel return pipe to the fuel pressure regulator and tighten the fuel return pipe fitting to 24 ft. lbs. (33 Nm).
  8.  
  9. Install the air cleaner resonator bracket and tighten the bracket side nut to 89 lb inches (10 Nm).
  10.  
  11. Tighten the bracket upper nut to 18 ft. lbs. (25 Nm).
  12.  
  13. Tighten the bracket bolt to 18 ft. lbs. (25 Nm).
  14.  
  15. Install the air cleaner outlet resonator.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Inspect for fuel leaks using the following procedure:


    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn OFF the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  

2.2L (VIN F) Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the vacuum pipe from the fuel pressure regulator.
  4.  
  5. Place a shop towel under the fuel pressure regulator in order to catch any fuel spillage.
  6.  
  7. Remove the retaining bolts from the fuel pressure regulator.
  8.  
  9. Remove the fuel pressure regulator.
  10.  
  11. Remove any seal or seal material left on the fuel rail (1).
  12.  

To install:


NOTE
Lubricate the O-rings with clean engine oil before installation.

  1. Install the small O-ring into the fuel rail.
  2.  
  3. Install the large O-ring into the fuel rail.
  4.  
  5. Install the fuel pressure regulator taking care not to disturb the O-rings.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6.  
  7. Install the fuel pressure regulator retaining bolts and tighten the retaining bolts to 44 lb inches (5 Nm). 
  8.  
  9. Connect the vacuum pipe to the fuel pressure regulator.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Inspect for fuel leaks using the following procedure:


    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn OFF the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  14.  

2.4L Engines
  1. Remove the fuel rail assembly.
  2.  
  3. Remove the attaching screw for the pressure regulator .
  4.  
  5. Remove the pressure regulator assembly from the fuel rail. Twist the assembly back and forth while pulling.
  6.  

To install:


NOTE
If the fuel pressure regulator is to be re-installed, inspect the filter screen for contamination. If the screen is contaminated, remove and discard the filter screen.

  1. Lubricate the new O-ring seal with clean engine oil and install the O-ring in the regulator.
  2.  
  3. Install the regulator.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


    NOTE
    Whenever there is not enough thread-locking material on the threads of reusable hardware, apply Loctite® 262 to ensure proper locking.

  4.  
  5. Install the pressure regulator attaching screw and tighten the screw to 84 lb inches (9.5 Nm).
  6.  
  7. Install the fuel rail assembly.
  8.  

 
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