Tracker 2000-2004

Fuel Pressure Regulator

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Removal & Installation



1.6L & 2.0L Engines
  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the throttle body.
  6.  
  7. Remove the fuel return line.
  8.  
  9. Remove vacuum line.
  10.  
  11. Remove the retaining bolts.
  12.  
  13. Remove the fuel pressure regulator.

    Click image to see an enlarged view

    Fig. Fuel pressure regulator retaining bolt (1), fuel return line (2), vacuum line (4), and fuel pressure regulator (5)-1.6L and 2.0L engines

  14.  

To install:

  1. Install a new O-ring.
  2.  
  3. Apply a thin coat of oil to the O-ring.
  4.  
  5. Install the fuel pressure regulator.
  6.  
  7. Install the retaining bolts and tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Install the throttle body.
  10.  
  11. Reconnect the fuel return line.
  12.  
  13. Reconnect the vacuum line.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine.
  18.  
  19. Check for leaks and repair as necessary.
  20.  

2.5L Engine
  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the vacuum hose from the fuel pressure regulator.
  6.  
  7. Remove the two bolts from the fuel pressure regulator.
  8.  
  9. Remove the fuel pressure regulator from the fuel rail.
  10.  
  11. Disconnect the fuel pressure regulator from the fuel return hose.

    Click image to see an enlarged view

    Fig. Fuel pressure regulator (1), fuel rail (2), and O-ring (3)-2.5L engine

  12.  

To install:

  1. Connect the fuel return hose to the fuel pressure regulator.
  2.  
  3. Install a new O-ring on the fuel pressure regulator.
  4.  
  5. Apply a thin coat of oil to the O-ring in order to ease installation.
  6.  
  7. Install the fuel pressure regulator into the fuel rail.
  8.  
  9. Secure the fuel pressure regulator to the fuel rail with the two bolts and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the vacuum line to the fuel pressure regulator.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Turn ON the ignition, leaving the engine OFF.
  16.  
  17. Turn ON the fuel pump with the scan tool.
  18.  
  19. Check for fuel leaks and repair as necessary.
  20.  

 
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