Toyota Matrix 2003-06

Fuel Pressure Regulator

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Removal & Installation



  1. Remove the fuel sender assembly.
  2.  
  3. Remove the bottom cap and the lower cushion from the fuel sender assembly .
  4.  
  5. Remove the fuel pressure regulator.
  6.  

To install:

  1. Apply gasoline to fuel pressure regulator O-ring, and install onto fuel pressure regulator.
  2.  
  3. Install the fuel pressure regulator into the fuel sender assembly.
  4.  
  5. Position the lower cushion on bottom of fuel pump, and install the lower cap to the sender assembly until the cap locks into place.
  6.  
  7. Install the fuel sender assembly to the fuel tank.
  8.  

AWD
  1. Remove the fuel sender assembly.
  2.  
  3. Remove the bottom cap and the lower cushion from the fuel sender assembly.
  4.  

To install:

  1. Apply gasoline to a new fuel pressure regulator O-ring.
  2.  
  3. Install the new O-ring onto the fuel pressure regulator.
  4.  
  5. Install the fuel pressure regulator into the fuel filter assembly.
  6.  
  7. Install the fuel pressure regulator into the fuel sender assembly.
  8.  
  9. Position the lower cushion on bottom of fuel pump, and install the lower cap to the sender assembly until the cap locks into place.
  10.  
  11. Install the fuel sender assembly to the fuel tank.
  12.  

FWD
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rear left hand seat cushion
  4.  
  5. Remove the rear service hole cover.
  6.  
  7. Disconnect the fuel pump and vapor pressure sensor connector.
  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Remove the 3 bolts and fuel tank protector.
  12.  
  13. Remove the tube joint clip, and pull the fuel tank main tube out.
  14.  
  15. Remove the 5 bolts and fuel tank vent tube set plate.
  16.  
  17. Pull the fuel pump assembly out.
    NOTE
    Make sure that the arm of the fuel sender gauge does not bend.

  18.  
  19. Remove the gasket from the fuel pump assembly.
  20.  
  21. Using a screwdriver, disconnect the 5 snap claws from the claw holes, and remove the fuel suction support.
  22.  
  23. Remove the fuel pump cushion rubber.
  24.  
  25. Disconnect the fuel sender gage connector.
  26.  
  27. Using a screwdriver with its tip wrapped in tape, unlock the fuel sender gage, and slide it remove.
  28.  
  29. Disconnect the fuel pump connector, using a screwdriver disconnect the claws retaining the fuel suction plate and remove the plate.
  30.  
  31. Remove the tube joint clip and pull out the vapor pressure sensor.
  32.  
  33. Remove the fuel pump harness from the suction plate.
  34.  
  35. Remove the fuel pump.
  36.  
  37. Remove the fuel pump filter by disengaging the clip and slide it from the pump.
  38.  
  39. Pull the fuel pressure regulator and O-Ring from the pump.
  40.  
  41. Install the set plate and tighten the bolts to 53 in. lbs. (6 Nm).
  42.  
  43. Install the fuel tank main tube.
  44.  
  45. Install the fuel tank protector.
  46.  
  47. Connect the fuel pump and vapor pressure sensor connector.
  48.  
  49. Install the rear service hole cover.
  50.  
  51. Install the rear left hand seat cushion and tighten the bolts to 3o ft. lbs. (41 Nm).
  52.  
  53. Connect the battery cable, start the vehicle and check for leaks.
  54.  

 
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