Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Fuel Pressure Regulator

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REMOVAL & INSTALLATION



1991-94 Models

See Figures 1 through 10

  1. Remove the air intake tube and resonator assembly.
  2.  
  3. Properly relieve the fuel system pressure. Refer to the procedure earlier in this section.
  4.  
  5. Remove the bolts from the fuel line clip.
  6.  
  7. Using a 15 / 16 in. (24mm) backup wrench to prevent damage to the inlet port and bracket, disconnect the fuel inlet and return lines from the pressure regulator/fuel rail assembly.
  8.  

If difficulty is encountered accessing the fuel return line nut, loosen and/or remove the fuel supply and rail attachment fasteners.

  1. Disengage the fuel pressure regulator vacuum hose.
  2.  
  3. Remove the regulator assembly attaching screw, then remove the regulator assembly. Plug the regulator port in the fuel rail with a clean rag to prevent system contamination.
  4.  
  5. Do not remove the O-ring from the retainer in the pressure regulator fuel outlet, unless it is damaged and requires replacing. Always remove and discard the O-ring from the fuel inlet.
  6.  

To install:
  1. Lubricate the new fuel inlet O-ring and, if necessary, the new outlet O-ring with clean engine oil, then install the O-ring(s) in the pressure regulator assembly.
  2.  
  3. Position the regulator assembly to the fuel rail. Coat the threads of the attaching bolt with Loctite® 242 or an equivalent threadlock, then install the bolt and tighten to 106 inch lbs. (12 Nm).
  4.  
  5. Connect the fuel pressure regulator vacuum hose.
  6.  
  7. Connect the fuel inlet and return lines, then tighten the lines to 133 inch lbs. (15 Nm) using a backup wrench to prevent port damage.
  8.  
  9. Cycle the ignition switch to prime the fuel system, then start the engine and check for fuel leaks.
  10.  
  11. Turn the ignition OFF and install the air intake tube and resonator assembly.
  12.  



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Fig. Fig. 1: Disconnect the air hose between the camshaft cover and air cleaner inlet hose



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Fig. Fig. 2: Loosen the air inlet hose clamp at the throttle body



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Fig. Fig. 3: Disconnect the air inlet hose at the throttle body and remove it from the vehicle



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Fig. Fig. 4: Loosen the supply and return lines from the pressure regulator/fuel rail assembly with the aid of a 15/16 in. (24mm) backup wrench-1991-94 vehicles



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Fig. Fig. 5: Disconnect the supply and return lines from the pressure regulator/fuel rail assembly



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Fig. Fig. 6: Disengage the fuel pressure regulator vacuum hose



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Fig. Fig. 7: Use a suitable wrench to loosen ...



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Fig. Fig. 8: ... and remove the mounting screw from the pressure regulator/fuel rail assembly



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Fig. Fig. 9: Remove the fuel pressure regulator assembly from the fuel rail



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Fig. Fig. 10: Always remove and discard the O-ring from the fuel inlet

1995-97 Models

See Figures 11, 12, 13, 14 and 15

  1. Remove the air intake tube, resonator assembly and PCV hose.
  2.  
  3. Properly relieve the fuel system pressure. Refer to the procedure in this section.
  4.  
  5. Remove the throttle cable bracket mounting bolts, disconnect the cable from the throttle lever and place over the intake manifold.
  6.  
  7. Disengage the fuel pressure regulator vacuum hose.
  8.  
  9. Remove and discard the retaining clip that secures the pressure regulator to the fuel rail socket.
  10.  
  11. Pull upward to remove the pressure regulator from the fuel rail socket. Do not use any tools for this step, or damage to the plastic socket will occur.
  12.  
  13. Remove and discard the following from the fuel rail socket or pressure regulator:

    Plastic backup ring
     
    Upper (large) O-ring
     
    Filter screen
     
    Lower (small) O-ring
     

  14.  


WARNING
When removing the filter screen, be careful not to drop the lower O-ring into the fuel rail. If dropped into the rail, the O-ring must be retrieved. If not retrieved, a new fuel rail must be used.

  1. Inspect the fuel rail socket for foreign material and clean if necessary. Be careful not to scratch the surfaces of the fuel rail that mate to the fuel pressure regulator O-rings.
  2.  

To install:
  1. Be sure to lubricate the upper and lower O-rings with clean engine oil before installing them onto the pressure regulator assembly.
  2.  
  3. When assembling the fuel pressure regulator, install the these new components in the following order:
    1. Plastic backup ring
    2.  
    3. Upper (large) O-ring
    4.  
    5. Filter screen
    6.  
    7. Lower (small) O-ring
    8.  

  4.  
  5. Position the fuel pressure regulator onto the fuel rail. Using hand pressure only, install the regulator assembly into the fuel rail socket. Carefully rotating the fuel pressure regulator one quarter turn will aid in the installation process.
  6.  
  7. Install the new fuel pressure regulator retaining clip. Be sure to install the retaining clip correctly-the lower side of the clip surrounds the fuel rail socket (down side) and the small side of the clip (top side) surrounds the regulator. The retaining clip must be fully secured over the fuel rail socket tabs and body of the pressure regulator.
  8.  
  9. Position the fuel pressure regulator vacuum hose nipple at a 10° angle to the fuel rail body.
  10.  
  11. With the engine OFF and the ignition switch in the ON position, pressurize the fuel system and check for leaks.
  12.  
  13. Connect the PCV and fuel pressure regulator vacuum hoses. Be sure that they are properly seated.
  14.  
  15. Place the throttle cable bracket into position and install mounting fasteners. Tighten the mounting fasteners to 19 ft. lbs. (25 Nm).
  16.  
  17. Connect the cable to the throttle lever.
  18.  
  19. Cycle the ignition switch ON for 5 seconds and then OFF for 10 seconds to prime the fuel system. Perform this procedure 2 more times, then start the engine and check for fuel leaks.
  20.  
  21. Turn the ignition OFF and install the air intake tube and resonator assembly.
  22.  



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Fig. Fig. 11: Remove and discard the fuel pressure regulator retaining clip



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Fig. Fig. 12: Components of the fuel pressure regulator assembly



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Fig. Fig. 13: Correct assembly of the fuel pressure regulator



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Fig. Fig. 14: Correct installation of the fuel pressure regulator retaining clip



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Fig. Fig. 15: Position the regulator vacuum hose nipple at a 10° angle to the fuel rail

1998 Models

The fuel pressure regulator on 1998 Saturn models is an integral component of the fuel filter assembly and can only be serviced as a single component. For servicing the fuel filter/pressure regulator, refer to General Information & Maintenance .

 
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