Fuel Pressure Regulator removal installation?

Fuel Pressure Regulator

• REMOVAL & INSTALLATION

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REMOVAL & INSTALLATION

See Figure 1

Fig. Fig. 1: Cutaway view of the fuel pressure regulator

Except the 4.0L SOHC (VIN E) Engine

See Figures 2 through 10

1. Depressurize the fuel system; remove shielding as needed.
2. Remove the vacuum line at the pressure regulator.

Fig. Fig. 2: Fuel pressure regulator on the 2.3L and 2.5L engine-3.0L and 5.0L engines are similar

Fig. Fig. 3: Fuel pressure regulator on the 2.9L engine

Fig. Fig. 4: Fuel pressure regulator on the 4.0L engine

Fig. Fig. 5: To remove the fuel pressure regulator, first remove the vacuum line from the regulator ...

Fig. Fig. 6: ... then loosen the fuel return line fitting ...

Fig. Fig. 7: ... and disconnect it from the regulator

3. If necessary, disconnect the fuel return line from the regulator.

Some engines use two standard hex head bolts to retain the regulator instead of the Allen® head screws.

Fig. Fig. 8: Remove the regulator attaching bolts ...

Fig. Fig. 9: ... then pull the regulator from the supply manifold using a slight rocking motion to unseat the O-ring seal

4. Remove the three Allen® head retaining screws from the regulator housing.
5. Remove the pressure regulator assembly, gasket and O-ring. Discard the gasket and check the O-ring for signs of cracks or deterioration.

Fig. Fig. 10: Inspect the regulator O-ring seal and replace it if needed. A small pick will aid in removing the old seal

To install:

6. Clean the gasket mating surfaces. If scraping is necessary, be careful not to damage the fuel pressure regulator or supply line gasket mating surfaces.
7. Lubricate the pressure regulator O-ring with light engine oil. Do not use silicone grease; it will clog the injectors.
8. Install the O-ring and a new gasket on the pressure regulator.
9. Install the pressure regulator on the fuel manifold and tighten the retaining screws to 27-40 inch lbs. (3-4 Nm) for all engines except the 4.0L (VIN X) engine, which is tightened to 70-97 inch lbs. (8-11 Nm).

On the 2.3L and 2.5L engine, install the fuel manifold shield and tighten the bolts to 15-3 ft. lbs. (1-30 Nm).

10. Install the vacuum line at the pressure regulator.
11. If removed, connect the fuel return line.
12. Build fuel pressure in the system by turning the ignition ON and OFF(without starting the engine) at least five times. Leave the ignition ON at least 5 seconds each time. Check for fuel leaks.

4.0L SOHC (VIN E) Engine

See Figures 11 and 12

On the 4.0L SOHC (VIN E) engine, the fuel pressure regulator is integral with the supply and return lines that are routed on the engine.

1. Depressurize the fuel system; remove shielding as needed.
2. Remove the upper intake manifold.
3. Disconnect the fuel pressure regulator vacuum line.
4. Disconnect the fuel supply and return lines.

Fig. Fig. 11: Remove the four bolts (arrows) that attach the regulator/fuel lines to the supply manifold

5. Remove the bolts and the fuel supply and return lines at the injection manifold.
6. Unbolt the upper fuel line support bracket from the valve cover.
7. Remove the fuel supply and return line assembly from the vehicle with the regulator assembly attached.

To install:

8. Clean the gasket mating surfaces. If scraping is necessary, be careful not to damage the fuel pressure regulator or supply line gasket mating surfaces.
9. Lubricate the pressure regulator O-ring with light engine oil. Do not use silicone grease; it will clog the injectors.

Fig. Fig. 12: Position the fuel pressure regulator assembly to the supply manifold (arrows)

10. Install the O-ring and a new gasket on the pressure regulator.
11. Install the fuel supply and return line assembly.
12. Fasten the upper fuel line support bracket to the valve cover.
13. Install the bolts that fasten the fuel supply and return lines to the injector manifold.
14. Connect the fuel supply and return lines.
15. Connect the vacuum line to the pressure regulator.
16. Install the upper intake manifold.
17. Build fuel pressure in the system by turning the ignition ON and OFF(without starting the engine) at least five times. Leave the ignition ON at least 5 seconds each time. Check for fuel leaks.

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