GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Fuel Pressure Regulator

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

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Fig. Fig. 1: View of the fuel rail and related system components-2.3L engine



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Fig. Fig. 2: Exploded view of the fuel rail and related components-3.1L (VIN T) engine shown



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Fig. Fig. 3: Fuel rail assembly-1995 3.4L engine shown



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Fig. Fig. 4: Cross-section view of the fuel pressure regulator assembly

On some applications, the pressure regulator and fuel rail are only available as an assembly. Check with your local parts retailer for parts availability and compatibility.

2.2L Engine
  1. Relieve the fuel system pressure as outlined earlier.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the vacuum hose from the regulator.
  6.  
  7. Place a rag under the connection and remove the fuel return pipe clamp.
  8.  
  9. Remove the fuel return pipe and O-ring from the regulator. Discard the O-ring.
  10.  
  11. Unfasten the pressure regulator bracket attaching screw, then remove the pressure regulator assembly and O-ring. Discard the O-ring.
  12.  

To install:
  1. Lubricate a new pressure regulator O-ring with clean engine oil, then install on the pressure regulator.
  2.  
  3. Install the pressure regulator assembly onto the manifold.
  4.  
  5. Install the pressure regulator bracket attaching screw coated with the appropriate thread locking material and tighten to 31 inch lbs. (3.5 Nm).
  6.  
  7. Connect the vacuum hose to the regulator.
  8.  
  9. Lubricate a new fuel return pipe O-ring with clean engine oil, then install on the end of the pipe.
  10.  
  11. Install the fuel return pipe to the pressure regulator and tighten the attaching nut to 22 inch lbs. (30 Nm).
  12.  
  13. Fasten the fuel return pipe clamp attaching nut to the lower manifold assembly.
  14.  
  15. Tighten the fuel filler cap.
  16.  
  17. Connect the negative battery cable and turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  18.  

2.8L, 3.1L and 3.4L Engines
EXCEPT 3.1L (VIN M) AND 1994-96 3.4L ENGINES
  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Disconnect the fuel feed line and return line from the fuel rail assembly; be sure to use a backup wrench on the inlet fitting to prevent turning.
  6.  
  7. Remove the fuel rail assembly from the engine.
  8.  

On some vehicles, it is possible to remove the pressure regulator with the fuel rail installed on the engine.

  1. With the fuel rail assembly removed from the engine, remove the pressure regulator mounting screw or retainer.
  2.  
  3. Remove the pressure regulator from the rail assembly by carefully twisting back and forth while pulling apart. Remove and discard the regulator O-rings.
  4.  

To install:
  1. Prior to assembling the pressure regulator to the fuel rail, lubricate the new rail-to-regulator O-ring seal with clean engine oil.
  2.  
  3. Place the O-ring on the pressure regulator and install the pressure regulator to the fuel rail.
  4.  
  5. Install the retainer or coat the regulator mounting screws with an approved tread locking compound and secure the pressure regulator in place. Tighten the mounting screws to 102 inch lbs. (11.5 Nm).
  6.  
  7. Install the fuel rail assembly to the engine, as outlined earlier.
  8.  
  9. Connect the fuel feed line and return line to the fuel rail assembly, use a backup wrench on the inlet fitting to prevent turning.
  10.  
  11. Connect the negative battery cable and turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  12.  

3.1L (VIN M) ENGINE
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the throttle body, as outlined earlier in this information.
  6.  
  7. Unfasten the fuel pressure regulator retaining screw.
  8.  
  9. Place a shop towel under the regulator to catch any fuel, then remove the pressure regulator from the rail using a twisting and pulling motion to remove it.
  10.  
  11. Remove the retainer and spacer from the fuel rail and discard.
  12.  
  13. Detach the fuel pressure regulator from the engine fuel return pipe.
  14.  
  15. Remove and discard the pressure regulator inlet O-ring.
  16.  

To install:
  1. Lubricate a new pressure regulator O-ring with clean engine oil and install on the regulator inlet.
  2.  


WARNING
The fuel return pipe must be connected before tightening the regulator attaching screw to prevent the regulator from rotating. Rotation of the regulator could damage the retainer and spacer bracket and lead to a fuel leak at the regulator inlet.

  1. Place a new retainer and spacer bracket into the slot on the fuel rail.
  2.  
  3. Install the pressure regulator to the fuel rail.
  4.  
  5. Connect the fuel return line to the regulator. Tighten the engine fuel return pipe nut to 13 ft. lbs. (17 Nm).
  6.  
  7. Attach the vacuum line to the regulator.
  8.  
  9. Install the pressure regulator retaining screw and tighten to 80 inch lbs. (9 Nm). Make sure the retainer and spacer bracket is engaged in the slots in the fuel rail. Grasp and pull on the regulator to make sure it is properly seated.
  10.  
  11. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  12.  
  13. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  14.  

1994-96 3.4L ENGINE
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the upper manifold assembly, as outlined in Engine & Engine Overhaul of this repair guide.
  6.  
  7. Unfasten the fuel pressure regulator bracket attaching screw.
  8.  
  9. Remove the regulator assembly and O-rings. Discard the O-rings.
  10.  

To install:
  1. Lubricate new pressure regulator O-rings with clean engine oil and install on the regulator.
  2.  
  3. Install the regulator and attaching screw. Tighten to 84 inch lbs. (9.5 Nm).
  4.  
  5. Install the upper manifold assembly.
  6.  
  7. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  8.  
  9. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  10.  

3.8L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Clean the dirt and grease from the regulator retaining ring.
  6.  
  7. Disconnect the vacuum line from the regulator.
  8.  
  9. Remove the snapring from the regulator. Wrap a towel around the regulator to catch any fuel that may escape.
  10.  
  11. Lift and twist the regulator to remove it from the fuel rail assembly. Remove and discard the regulator O-rings.
  12.  
  13. Cover all openings with masking tape to prevent dirt entry.
  14.  

To install:
  1. Lubricate new O-ring seals with clean engine oil, then install on the regulator.
  2.  
  3. Install the regulator into the regulator housing and secure with the snapring.
  4.  
  5. Attach the vacuum line to the regulator.
  6.  
  7. Connect the negative battery cable, then install the fuel filler cap, if not done already.
  8.  
  9. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.
  10.  

 
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