GM Corsica/Beretta 1988-1996 Repair Guide

Fuel Pressure Regulator

Print

REMOVAL & INSTALLATION



2.3L Engines

See Figures 1, 2, 3 and 4

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel rail assembly from the cylinder head.
  6.  
  7. Remove the pressure regulator attaching screws.
  8.  
  9. Twist back and forth and remove the regulator from the fuel rail.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Cross-sectional view of a fuel pressure regulator - 2.3L engine

To install:
  1. Lubricate the new rail to the regulator inlet fitting O-ring seal with clean engine oil and install in the regulator.
  2.  
  3. Install the pressure regulator by aligning the retainer and spacer assembly mounting holes and tightening the retaining screws, with thread locking material, to 49 inch lbs. (5.5 Nm) for 1990 vehicles and 102 inch lbs. (11.5 Nm) for 1991-94 vehicles.
  4.  
  5. Install the fuel rail assembly.
  6.  
  7. Connect the negative battery cable. Tighten the fuel filler cap.
  8.  
  9. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Turn the ignition switch to the ON position again and check for leaks.
  10.  

2.8L and 3.1L Engines

See Figures fig40 and 41

1988-93 VEHICLES
  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the fuel rail and place on a suitable workbench.
  6.  
  7. Remove the fuel inlet and outlet fittings and gaskets.
  8.  
  9. Remove the pressure regulator bracket attaching screws and mounting bracket.
  10.  
  11. Remove the right and left hand fuel rail assemblies from the pressure regulator assembly.
  12.  
  13. Remove the base-to-rail connectors from the regulator or rails.
  14.  
  15. Disassemble the connector O-rings from the base to rail connectors.
  16.  
  17. Remove the fuel return O-ring from the fuel rails.
  18.  

To install:
  1. Lubricate new fuel return O-rings with clean engine oil and install on the fuel rails.
  2.  
  3. Lubricate new connector O-rings with clean engine oil and install to the base-to-rail connectors.
  4.  
  5. Install the base to rail connectors in the regulator assembly.
  6.  
  7. Install 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. (3.2 Nm).
  10.  
  11. Install new fuel inlet and outlet fitting gaskets and tighten the fittings to 20 ft lbs. (27 Nm) for 1988 vehicles or, for 1989-96 vehicles, tighten the fuel inlet fitting to 35 ft. lbs. (48 Nm) and the fuel outlet fitting to 30 ft. lbs. (40 Nm).
  12.  
  13. Install the fuel rail assembly.
  14.  
  15. Connect the negative battery cable. Tighten the fuel filler cap.
  16.  
  17. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Turn the ignition switch to the ON position again and check for leaks.
  18.  

1994-96 VEHICLES
  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Remove the upper intake manifold.
  6.  
  7. Disconnect the fuel pressure regulator vacuum line.
  8.  
  9. Unfasten the pressure regulator retaining screw.
  10.  
  11. Position a shop towel under the regulator, to catch any spilled fuel, then lift and twist the regulator to remove it from the fuel rail.
  12.  
  13. Remove and discard the retainer and spacer bracket from the fuel rail.
  14.  
  15. Remove the fuel pressure regulator from the engine fuel return pipe.
  16.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the fuel pressure regulator from the fuel rail assembly

  1. Remove and discard the pressure regulator inlet O-ring.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Remove and discard the pressure regulator O-ring

  1. Check the filter screen for contamination. If contamination is found, discard the filter screen.
  2.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the fuel pressure regulator attachment - 1994-96 vehicles

To install:
  1. Lubricate a new pressure regulator inlet O-ring with clean engine oil, then install on the regulator inlet.
  2.  
  3. Install a new retainer and spacer bracket into the slot on the fuel rail.
  4.  
  5. Position the pressure regulator to the fuel rail. Install the engine fuel return pipe nut to 13 ft. lbs. (17 Nm).
  6.  
  7. Install the pressure regulator attaching screw. Connect the vacuum line to the regulator. Tighten the regulator attaching screw to 6 ft. lbs. (8.5 Nm).
  8.  
  9. Make sure the retainer and spacer bracket is engaged in the slots in the fuel rail. Pull on the regulator to be sure it is properly seated.
  10.  
  11. Connect the negative battery cable. Tighten the fuel filler cap.
  12.  
  13. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Turn the ignition switch to the ON position again and check for leaks.
  14.  

 
label.common.footer.alt.autozoneLogo