GM Corvette 1984-1996 Repair Guide

Fuel Pressure Regulator

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REMOVAL & INSTALLATION



5.7L (VIN 8) Engine

See Figure 1

The pressure regulator and base are factory adjusted and serviced as a complete assembly only. Do not try to remove the regulator cover.

1985-88 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the fuel rail from the vehicle, as outlined earlier in this section.
  6.  
  7. Remove the front crossover tube retaining attaching screw and crossover tube retainer from the right hand rail side.
  8.  
  9. Unfasten the retainer-to-base screw assembly and rear crossover tube retaining from the pressure regulator and base assembly.
  10.  
  11. Separate the left hand fuel rail and plug assembly from the right hand fuel rail and plug assembly.
  12.  
  13. Remove the bracket-to-rail attaching screw, 2 bracket-to-base screws and the regulator and base bracket.
  14.  
  15. Unfasten the screw that attaches the fuel outlet tube to the right hand rail.
  16.  
  17. Remove the base-to-right hand rail assembly.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: Typical fuel pressure regulator assembly-5.7L (VIN 8) engine

  1. Twist the regulator and base assembly to the remove it from the fuel outlet tube.
  2.  
  3. Unplug the base-to-rail connector.
  4.  
  5. Remove and discard the O-ring seals from the following components, noting the location and sizes of the O-rings to ensure proper placement during installation:

    Connector
     
    Fuel outlet tube
     
    Rear crossover tube
     
    Front crossover tube
     

  6.  
  7. Check the O-rings and sealing surfaces for damage that may prevent proper sealing.
  8.  
  9. Installation is the reverse of the removal procedure. Tighten the retaining screws to 44 inch lbs. (5 Nm).
  10.  
  11. Connect the negative battery cable, then turn the ignition to the ON position and check for fuel leaks.
  12.  

1989-91 vehicles
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the fuel rail from the vehicle, as outlined earlier in this section.
  6.  
  7. Remove the rear crossover retainer-to-regulator base attaching screw and retainer.
  8.  
  9. Disconnect the rear crossover tube and O-ring from the regulator base. Discard the O-ring.
  10.  
  11. Unfasten the pressure regulator bracket screws, then remove the bracket.
  12.  
  13. Remove the regulator base-to-rail screw.
  14.  
  15. Remvoe the pressure regulator and base assembly. Separate the regulator base from the fuel rail, then disconnect from the fuel outlet tube.
  16.  
  17. Remove and discard the fuel outlet tube O-ring.
  18.  
  19. Detach the base-to-rail connector. Remove and discard the O-rings.
  20.  
  21. Installation is the reverse of the removal procedure. Tighten the retaining screws to 44 inch lbs. (5 Nm).
  22.  
  23. Connect the negative battery cable, then turn the ignition to the ON position and check for fuel leaks.
  24.  

5.7L (VIN P and 5) Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the left fuel rail cover from the vehicle.
  6.  
  7. Disconnect the pressure regulator vacuum line.
  8.  
  9. Remove the fuel outlet tube retainer clip, then disconnect the fuel outlet tube from the pressure regulator.
  10.  
  11. Unfasten the pressure regulator attaching screw, then remove the regulator from the fuel rail.
  12.  
  13. Remove and discard the pressure regulator inlet O-ring and the fuel outlet tube O-ring.
  14.  
  15. Chech the filter screen for contamination and replace if dirty.
  16.  

To install:
  1. Lubricate new O-rings with clean engine oil, then install on the pressure regulator and fuel outlet tube.
  2.  
  3. Push the pressure regulator into the fuel rail.
  4.  
  5. Install the pressure regulator attaching screw and tighten to 89 inch lbs.
  6.  
  7. Install the fuel outlet tube into the regulator, then secure with the retaining clip. Tighten the tube retainer screw to 44 inch lbs. (5 Nm).
  8.  
  9. Connect the vacuum line to the regulator.
  10.  
  11. Tighten the fuel filler cap, then connect the negative battery cable.
  12.  
  13. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.
  14.  
  15. Install the left fuel rail cover.
  16.  

5.7L (VIN J) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the intake plenum and fuel rail assembly.
  6.  
  7. Remove and discard the O-ring seals from the injector housings.
  8.  

To remove the pressure regulator, you must remove the left hand fuel rail and left hand fuel return tube. The fuel inlet and outlet tube can stay attached to the right hand fuel rail.

  1. Remove the crossover tube retaining screw and retainer from the left hand rail.
  2.  
  3. Remove the left hand fuel rail assembly.
  4.  
  5. Remove the left hand fuel return tube retainer attaching screw.
  6.  
  7. Remove the left hand fuel return tube.
  8.  
  9. Remove the fuel inlet tube retainer attaching screw and retainer from the regulator base.
  10.  
  11. Remove the fuel return tube retainer attaching screw (right hand side) and tube retainer.
  12.  
  13. Remove the pressure regulator assembly. Remove and discard the O-rings from the fuel tubes.
  14.  

To install:

CAUTION
To reduce the chance of fire and/or personal injury, do NOT tighten the crossover tube retainer attaching screws until left hand fuel rail has been installed. Failure to do so could cause damage to the O-ring seals or inlet/outlet tube, causing a fuel leak.

  1. Lubricate new O-rings with clean engine oil, then install on the fuel tubes.
  2.  
  3. Install the pressure regulator assembly to the right hand fuel return tube and fuel outlet tube.
  4.  
  5. Install the regulator tube retainer and fuel return tube retainer attaching screw (right side). Finger tighten the attaching screw.
  6.  
  7. Instlal the fuel inlet tube retainer and attaching screw to the regulator, then finger tighten the screw.
  8.  
  9. Attach the left hand fuel return tube to the regulator base.
  10.  
  11. Install the left hand fuel return tube retainer attaching screw and finger tighten the screw.
  12.  
  13. Instal the left hand fuel tail assembly.
  14.  
  15. Instlal the crossover tube and attaching screw.
  16.  

When tighten the fuel inlet tube retainer screw, hold the pressure regulator and fuel inlet tube retainer in place to avoid side loading the regulator/fuel tube O-rings and inlet/outlet tube assembly.

  1. Tighten the fuel inlet tube retainer attaching screws to 44 inch lbs. (5 Nm). Tighten the remaining retainer attaching screw to 44 inch lbs. (5 Nm).
  2.  
  3. Lubricate new injector housing O-ring seals with clean engine oil, then install.
  4.  
  5. Instlal the fuel rail, then connect the negative battery cable.
  6.  
  7. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks. Disconnect the negative battery cable.
  8.  
  9. Instal the intake plenum, tighten the fuel filler cap, then connect the negative battery cable.
  10.  

 
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