Mazda Trucks 1987-1993 Repair Guide

Fuel Pressure Regulator

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REMOVAL & INSTALLATION



4-Cylinder Engines

See Figure 1

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the vacuum hose.
  4.  
  5. Disconnect the fuel return hose.
  6.  



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Fig. Fig. 1: Disconnect the vacuum and fuel hoses (1), remove the fuel pressure regulator (2)

  1. Unbolt and remove the unit.
  2.  
  3. Install in the reverse order. Tighten the bolts to 95 inch lbs. (11 Nm).
  4.  

3.0L Engine

Refer to Fuel Charging Assembly Removal and Installation procedure above.

4.0L Engine

See Figure 2

  1. Depressurize the fuel system.
  2.  


CAUTION
The fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Remove the vacuum and fuel lines at the pressure regulator.
  2.  
  3. Remove the 2 or 3 Allen retaining screws from the regulator housing.
  4.  
  5. Remove the pressure regulator assembly, gasket and O-ring. Discard the gasket and check the O-ring for signs of cracks or deterioration.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: Fuel pressure regulator components

To install:
  1. Clean the gasket mating surfaces. If scraping is necessary, be careful not to damage the fuel pressure regulator or supply line gasket mating surfaces.
  2.  
  3. Lubricate the pressure regulator O-ring with light engine oil. Do not use silicone grease; it will clog the injectors.
  4.  
  5. Install the O-ring and a new gasket on the pressure regulator.
  6.  
  7. Install the pressure regulator on the fuel manifold and tighten the retaining screws to 6-8 ft. lbs. (8-11 Nm).
  8.  
  9. Install the vacuum and fuel lines at the pressure regulator. Build up fuel pressure by turning the ignition switch ON and OFF at least 6 times, leaving the ignition on for at least 5 seconds each time. Check for fuel leaks.
  10.  

 
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