GM Cavalier/Sunfire 1995-2000 Repair Guide

Fuel Pressure Regulator

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REMOVAL & INSTALLATION



2.3L/2.4L Engines

See Figure 1


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



Click image to see an enlarged view

Fig. Fig. 1: The fuel pressure regulator is located on the fuel rail-1995 2.3L engine shown

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel rail assembly from the vehicle.
  6.  
  7. Unfasten the pressure regulator attaching screw, then remove the regulator, twisting it back and forth while pulling it apart. Remove and discard O-ring.
  8.  
  9. If the regulator is to reinstalled, inspect the filter screen for contamination and discard if necessary.
  10.  

To install:
  1. Lubricate a new rail-to-regulator inlet fitting O-ring seal with clean engine oil, then install in regulator.
  2.  
  3. Install the regulator assembly. Align with the retainer and spacer assembly mounting hole. Coat the retaining screw with Loctite® 262 or equivalent, then tighten to 102 inch lbs. (15 Nm).
  4.  
  5. Install the fuel rail assembly.
  6.  
  7. Connect the negative battery cable.
  8.  

1998-00 2.2L Engine

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: The fuel pressure regulator (2) has an O-ring (4) at the top where it enters the fuel rail (1), and is held by a retaining screw (3) on the bracket

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner outlet resonator.
  6.  
  7. Remove the fuel rail bracket.
  8.  
  9. Remove the pressure regulator bracket attaching screw.
  10.  
  11. Remove the pressure regulator from the fuel rail.
  12.  

To install:
  1. Install the pressure regulator using a new O-ring.
  2.  
  3. Tighten the pressure regulator bracket retaining bolt to 31 inch lbs. (4 Nm).
  4.  
  5. Install the fuel rail bracket bolts and nuts and tighten to:

    Tighten the front nuts to 89 inch lbs. (10 Nm).
     
    Tighten the remaining bolts and nuts to 18 ft. lbs. (25 Nm).
     

  6.  
  7. Install the air cleaner outlet resonator.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the vehicle and check for leaks.
  12.  

 
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