GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Fuel Pressure Regulator

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REMOVAL & INSTALLATION




CAUTION
To reduce the risk of fire or personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system.

1.8L And 2.0L OHC Engines
EXCEPT 2.0L (VIN H) ENGINES
  1. Relieve fuel system pressure.
  2.  
  3. Remove pressure regulator from fuel rail. Place a rag around the base of the regulator to catch any spilled fuel.
  4.  
  5. Installation is the reverse of removal procedure.
  6.  

2.0L (VIN H) ENGINES

See Figure 1

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Cross-sectional view of the fuel pressure regulator

  1. Remove the air duct and air cleaner cover.
  2.  
  3. Disconnect the vacuum hose from the pressure regulator.
  4.  
  5. Using a back-up wrench, remove the fuel return pipe at the pressure regulator.
  6.  
  7. Unfasten the pressure regulator attaching screw, then remove the regulator from the fuel rail, twisting it back and forth while pulling it apart.
  8.  

To install:
  1. If there is not enough thread locking material on the threads of the retaining screw, apply Loctite® 262 or equivalent to the threads.
  2.  
  3. The remainder of installation is the reverse of the removal procedure.
  4.  

2.8L and 3.1L Engines
1985-86 VEHICLES

The pressure regulator is factory adjusted and is not serviceable. Do not attempt to remove the regulator from the fuel rail.

1987-94 VEHICLES

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Location of the fuel pressure regulator - 1994 3.1L engine shown

  1. Remove the intake manifold plenum and the fuel rail, as outlined in this section.
  2.  
  3. Unfasten and remove the fuel inlet and outlet fittings and gaskets.
  4.  
  5. Unfasten the pressure regulator bracket attaching screws and mounting bracket.
  6.  
  7. Remove the right and left hand fuel rail assemblies from the pressure regulator assembly.
  8.  
  9. Remove the base-to-rail connectors from the regulator or rails.
  10.  
  11. Disassemble connector O-rings from the base to rail connectors.
  12.  
  13. Remove the fuel return O-ring from the fuel rails. Discard all O-rings.
  14.  

To install:
  1. Lubricate new fuel return O-rings with engine oil and install on the fuel rails.
  2.  
  3. Lubricate new connector O-rings with engine oil and install to the base to rail connectors.
  4.  
  5. Install the base-to-rail connectors in the regulator assembly.
  6.  
  7. Fasten the right and left hand fuel rail assemblies to the pressure regulator assembly.
  8.  
  9. Install the pressure regulator mounting bracket with the attaching screws. Tighten the screws to 28 inch lbs. (3 Nm).
  10.  
  11. Connect new fuel inlet and outlet fitting gaskets and tighten the fittings to 20 inch lbs. (2.2 Nm).
  12.  
  13. Install the fuel rail and intake manifold plenum.
  14.  
  15. Connect the negative battery cable.
  16.  

This test must be done before the engine is started and requires the use of a Tech 1® scan tool.

  1. If equipped with the 3.1L engine, perform the idle learn procedure to allow the ECM/PCM memory to be updated with the correct IAC valve pintle position and provide for a stable idle speed.
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  

 
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