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Fuel Pressure Regulator Replacement
 
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Pelican Technical Article:

Fuel Pressure Regulator Replacement

Jared Fenton

Time:

1 hour1 hr

Tab:

$40

Talent:

**

Tools:

Large flathead screwdriver, silicone grease

Applicable Models:

A6 2.7T (1997-04)
A6 2.8 (1997-02)
A6 3.0L (2002-04)
S6 4.2 (1997-04)

Parts Required:

Fuel Pressure Regulator

Hot Tip:

Make sure engine is cold before replacement

Performance Gain:

Better running car

Complementary Modification:

Replace fuel filter

The fuel pressure regulator (FPR) is an occasional source of frustration for the do-it-yourselfer. It may not show any obvious signs of failure, leaving you puzzled when your car stumbles on acceleration. Testing a regulator can be a bit difficult as sometimes the fault won't appear until the car has reached a certain temperature or a particular vacuum value.

The first step in diagnosis is to go over the basics. Is the fuel pump operating? Is the fuel filter clogged? Is there actually any fuel in the vehicle? Believe it or not, many people overlook these steps. The next step in determining if the regulator is bad is to check the fuel pressure on the car. Make sure you have a gauge that is rated for fuel injection pressures (at least 50 psi) and that all connections to the gauge are correct. See our article on Checking Fuel Pressure for more information.

Switch the key on and off several times to energize the fuel pump. This builds up pressure in the fuel rail and begins to register on the gauge. The system operating pressure is 35: 40 psi. If the operating pressure is below 35 psi or fluctuates wildly, it is probably a good bet that the regulator is bad. If you pull off the vacuum connection to the regulator and there is fuel dribbling from the nipple, the diaphragm inside has failed and the regulator must be replaced.

Be prepared: Work in a well-ventilated area. Keep a fire extinguisher near you at all times and know how to use it correctly. Don't have any sparks or open flame around. You will be working around gasoline. It is better to be prepared than have that one time where everything goes wrong.

Keep in mind that you will need to remove the upper engine covers to access the FPR. See our article on Engine Cover Removal for more information.

Remove the vacuum hose (green arrow) that attaches to the nipple on the fuel pressure regulator.
Figure 1

Remove the vacuum hose (green arrow) that attaches to the nipple on the fuel pressure regulator.

Once the vacuum connection is removed, locate the locking pin (green arrow) that holds the regulator in place.
Figure 2

Once the vacuum connection is removed, locate the locking pin (green arrow) that holds the regulator in place. Use a large flathead screwdriver to pull the locking pin out. It is also a good idea to clean any grime or dirt that has accumulated around the regulator to prevent it from falling inside the fuel rail.

Now pull the regulator up and out of its holder on the fuel rail.
Figure 3

Now pull the regulator up and out of its holder on the fuel rail. This may take a bit of effort. Be sure that the mounting bore is clean before installing the new regulator. You may also want to put a very small coat of silicone grease on the O-ring (green arrow). This will help to seat the regulator. When the new regulator is installed, press it down with enough force to allow the locking pin to slide back in place.

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Page last updated: Sat 10/21/2017 03:16:54 AM