GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Sunfire 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Pressure Regulator Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the vacuum pipe from the fuel pressure regulator.
  3. Place a shop towel under the fuel pressure regulator in order to catch any fuel spillage.

    4. Object Number: 783969 Size: SH
  4. Remove the retaining bolts from the fuel pressure regulator.

    5. Object Number: 783968 Size: SH
  5. Remove the fuel pressure regulator.
  6. Remove any seal or seal material left on the fuel rail (1).

Installation Procedure

    Object Number: 783968 Size: SH

    Important: Lubricate the O-rings with clean engine oil before installation.

  1. Install the small O-ring into the fuel rail (1).
  2. Install the large O-ring into the fuel rail.

    3. Object Number: 783969 Size: SH
  3. Install the fuel pressure regulator taking care not to disturb the O-rings.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the fuel pressure regulator retaining bolts.

    5. Tighten
    Tighten the retaining bolts to 5 N·m (44 lb in). 

  5. Connect the vacuum pipe to the fuel pressure regulator.
  6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  7. Inspect for leaks using the following procedure:
    8. 7.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    7.2. Turn OFF the ignition for 10 seconds.
    7.3. Turn ON the ignition.
    7.4. Inspect for fuel leaks.
  8. Place the shop towel into a suitable storage container.