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Fuel Pressure Regulator Replacement
 
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Pelican Technical Article:

Fuel Pressure Regulator Replacement

Steve Vernon

Time:

30 minutes30 mins

Tab:

$100 to $200

Talent:

*

Tools:

10mm socket, flathead screwdriver

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

New fuel pressure regulator

Hot Tip:

Work on a cold engine

Performance Gain:

Car runs like normal again

Complementary Modification:

Replace fuel injectors

Fuel pressure regulators are an occasional source of frustration for the do-it-yourselfer. Sometimes, they don't show any obvious indication 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.

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 fuel pressure regulators for the 944 are not cheap, so before you change yours out make sure it is faulty and check the fuel pressures. Please see our article on fuel pressure testing for additional assistance.

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 and if you smoke now would be a really good time to quit: at least for the half hour it might take you to perform this job.

Just as with the fuel filter, injectors, or any other component of the fuel system, it's best to relieve the fuel system of any pressure before you go opening it up. You can do this by opening the fuel filler cap and/or removing the fuel pump relay from the car's fuse panel and then starting the car and allowing it to idle until it runs out of fuel. Also, be sure to use some protective gloves and goggles whenever you're working with fuel.

Some fuel will spill out no matter what you do. Be prepared to catch it with some rags and dispose of the rags in accordance with the regulations in your area. Never store fuel soaked rags anywhere; they are very dangerous.

Locate the fuel pressure regulator.
Figure 1

Locate the fuel pressure regulator. It will be different on some models (turbo, 8 valve and 16 valve) but it is always on the fuel rail and most times on the rear of the rail (red arrow). Make sure it is not the fuel pressure damper, which will be at the front of the fuel rail on the supply line (yellow arrow).

To help decrease the pressure in the fuel rail, you will want to remove the fuel pump relay and turn the engine over a couple of times until it runs out of fuel.
Figure 2

To help decrease the pressure in the fuel rail, you will want to remove the fuel pump relay and turn the engine over a couple of times until it runs out of fuel. Begin by locating the relay panel; in earlier cars it will be up under the dash. In later cars it will be in the rear left side of the engine bay by the base of the windshield. Remove the cover (red arrow).

Check with your manual.
Figure 3

Check with your manual. Locate the fuel pump relay and remove it (red arrow). Crank the ignition over a few times until the car runs out of fuel. Fuel will still escape while performing this job, but this will help relieve some of the pressure.

The pressure regulator bolts to the rear of the fuel rail where the fuel enters (red arrow, hidden by bracket); there is also a vacuum line (yellow arrow) and the fuel return line attached to it (green arrow).
Figure 4

The pressure regulator bolts to the rear of the fuel rail where the fuel enters (red arrow, hidden by bracket); there is also a vacuum line (yellow arrow) and the fuel return line attached to it (green arrow).

Pull the vacuum line from the regulator (red arrow).
Figure 5

Pull the vacuum line from the regulator (red arrow).

Use a flathead screwdriver and remove the clamp from the return fuel line and slip the line off the regulator (red arrow).
Figure 6

Use a flathead screwdriver and remove the clamp from the return fuel line and slip the line off the regulator (red arrow).

Remove the two 10mm bolts holding the regulator to the fuel rail (red arrows).
Figure 7

Remove the two 10mm bolts holding the regulator to the fuel rail (red arrows).

Wiggle and pull the regulator from the rail.
Figure 8

Wiggle and pull the regulator from the rail. There will be fuel in both the regulator and rail, so be prepared to catch and dispose of it. There is a rubber O-ring on the base of the regulator that fits into the fuel rail. Put a little fuel on the ring when installing to help lubricate it (red arrow). Installation is the reverse of removal.








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