How to Replace the Fuel Pump Regulator on a Chevy Cavalier
Chevrolet Cavaliers equipped with electronic fuel injection utilize a high pressure electric fuel pump mounted inside the gas tank. Fuel is pumped to the engine and whatever is unused is returned to the gas tank through the fuel return pipe. The fuel pressure regulator is mounted between the fuel return pipe and lower intake manifold; it is powered by a vacuum supplied by the engine. The fuel pressure regulator restricts the amount of fuel returning to the gas tank, in order to increase the pressure available for the fuel injector.
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Things You'll Need
- Wrench set
- Socket set
- Flat blade screwdriver
- Phillips screwdriver
- Needle nose pliers
- Replacement o-rings
- Replacement fuel pressure regulator
Instructions
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Relieving Fuel System Pressure
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1
Loosen the fuel filler cap.
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2
Remove the fuel pump fuse from the fuse block located underneath the dash on the driver's side of the passenger compartment. The fuel pump fuse will be labeled.
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3
Start the engine. Let the engine run until it stalls out after all the fuel in the fuel lines is consumed.
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4
Disconnect the ground cable from the negative battery terminal.
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5
Replace the fuel pump fuse in the fuse block.
Removing the Fuel Pressure Regulator
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6
Disconnect the vacuum line from the top of the fuel pressure regulator by removing the retaining clamp and pulling the vacuum line off the regulator.
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7
Place a shop rag underneath the fuel pressure regulator and use a wrench to remove the fuel return pipe clamp. It will be located on the bottom of the fuel pressure regulator.
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8
Separate the fuel return pipe from the fuel pressure regulator and discard the o-ring seal.
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9
Remove the screw that secures the fuel pressure regulator to the lower intake manifold.
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10
Remove the fuel pressure regulator, and the o-ring that fits between the regulator and the lower intake manifold. Discard the o-ring.
Installing a New Fuel Pressure Regulator
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11
Lubricate the new o-ring and install it between the fuel pressure regulator and the lower intake manifold.
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12
Reinstall the screw that secures the fuel pressure regulator to the lower intake manifold.
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13
Lubricate the new o-ring and install it between the bottom of the fuel pressure regulator and the fuel return pipe.
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14
Reinstall the fuel return pipe clamp on the bottom of the fuel pressure regulator.
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15
Reconnect the vacuum line to the top of the fuel pressure regulator by sliding the rubber line onto the top of the fitting and reinstalling the hose clamp.
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16
Reconnect the ground cable to the negative battery terminal.
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17
Tighten the fuel filter cap.
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18
Run the engine and visually inspect for leaks.
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1
Tips & Warnings
Place a waste oil collection pan directly underneath the fuel pressure regulator while removing it to collect any fuel that leaks out.
Gasoline and gasoline vapors are highly flammable. Do not smoke or allow anyone around you to smoke while servicing the fuel system. Be aware of any sources of spark or heat, such as space heaters or drop lights. Gasoline vapors are highly toxic to humans. Always work in a well-ventilated area.
