Malibu 2001-2005

Fuel Pressure Regulator

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Removal & Installation



  1. Relieve fuel system pressure.
  2.  
  3. Disconnect the fuel pressure regulator vacuum line.
  4.  
  5. Remove the fuel pressure regulator retaining screw.
  6.  
  7. Using a shop towel to catch any spilled fuel, lift and twist the fuel pressure regulator in order to remove the fuel pressure regulator from the fuel rail.
  8.  
  9. Remove the retainer and spacer bracket from the rail and discard.
  10.  
  11. Remove the fuel pressure regulator from the engine fuel return pipe.
  12.  
  13. Remove the fuel pressure regulator inlet O-ring and discard.

    Click image to see an enlarged view

    Fig. Removal and installation of the fuel pressure regulator

  14.  

To install:


CAUTION
Connect the fuel return line before tightening the regulator attaching screw in order 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.


NOTE
Do not use compressed air in order to test or clean a fuel pressure regulator as damage to the fuel pressure regulator may result.


NOTE
Clean the fuel pressure regulator filter screen with gasoline if necessary


NOTE
Do not immerse the fuel pressure regulator in a solvent bath in order to prevent damage to the fuel pressure regulator

  1. Check the filter screen for contamination. If contaminated, replace the fuel pressure regulator.
  2.  
  3. Lubricate the new pressure regulator inlet O-ring with clean engine oil and install on the regulator inlet.
  4.  
  5. Install the fuel return pipe to the regulator.
  6.  
  7. Install the new retainer and spacer bracket into the slot on the fuel rail.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Install the pressure regulator to fuel rail, and tighten the engine fuel return pipe nut to 13 ft. lbs. (17 Nm).

  8.  
  9. Connect the fuel pressure regulator vacuum line.
  10.  
  11. Install the pressure regulator attaching screw, and tighten the fuel pressure regulator attaching screw to 76 lb inches (8.5 Nm).
  12.  
  13. Inspect and verify that the retainer and spacer bracket is engaged in the slots in fuel rail. Grasp and pull on the regulator to ensure that the regulator is properly seated.
  14.  
  15. Inspect for fuel leaks using the following procedure:


    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn OFF the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  16.  

The fuel pressure regulator is contained in the fuel pump module near the fuel pump outlet. The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure on the other side. The fuel pressure regulator is not vacuum biased. Fuel pressure is controlled by a pressure balance across the regulator. The fuel system pressure is constant.

 
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