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Pelican Technical Article:

Fuel Pressure Regulator Replacement

Steve Vernon

Time:

15 minutes15 mins

Tab:

$30

Talent:

*

Tools:

Pliers, Philips head screw driver

Applicable Models:

VW Golf GTI (2000)
VW Golf GTI 1.8T (2002-05)
VW Golf GTI 20th Anniversary (2003)
VW Golf GTI 337 (2002)
VW Golf GTI GLS (2001)

Parts Required:

New 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. If you have a new fuel filter and the pump is operating it can be easier and cheaper in the long run to replace the fuel pressure regulator than it is to perform all the fuel system pressure tests to find out if it is bad.

Be prepared: Work in a well ventilated area. Keep a fire extinguisher near you at all times and know how to use it correctly. No 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 fuse 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.

Begin by remove the main engine cover. There are four plastic screws; turn them 90 degrees with a Philips head screw driver and remove the cover from the engine.

Locate the pressure regulator on the left side of the fuel rail.

Remove the vacuum hose from the top of the regulator by simply pulling it off of the nipple.

The regulator is held in place by a circlip. You can pry this out using a set of pliers or a screwdriver.

Before you remove the regulator, it is a good idea to clean any grime or dirt that has accumulated around the regulator to prevent it from falling inside the fuel rail. Grab the outside body of the regulator and wiggle and pull it from the housing.

Remove the old regulator from the housing and make sure you clean the mounting surface of the housing before you install the regulator.

Begin by remove the main engine cover.
Figure 1

Begin by remove the main engine cover. There are four plastic screws (red arrows); turn them 90 degrees with a Philips head screwdriver and remove the cover from the engine.

Locate the pressure regulator (red arrow) on the left side of the fuel rail.
Figure 2

Locate the pressure regulator (red arrow) on the left side of the fuel rail.

Remove the vacuum hose (red arrow) from the top of the regulator by simply pulling it off of the nipple (red nipple).
Figure 3

Remove the vacuum hose (red arrow) from the top of the regulator by simply pulling it off of the nipple (red nipple).

The regulator is held in place by a circlip (red arrow).
Figure 4

The regulator is held in place by a circlip (red arrow). You can pry this out using a set of pliers or a screwdriver.

Before you remove the regulator, it is a good idea to clean any grime or dirt that has accumulated around the regulator to prevent it from falling inside the fuel rail.
Figure 5

Before you remove the regulator, it is a good idea to clean any grime or dirt that has accumulated around the regulator to prevent it from falling inside the fuel rail. Grab the outside body of the regulator (red arrow) and wiggle and pull it from the housing.

Remove the old regulator (red arrow) from the housing and make sure you clean the mounting surface (yellow arrow) of the housing before you install the regulator.
Figure 6

Remove the old regulator (red arrow) from the housing and make sure you clean the mounting surface (yellow arrow) of the housing before you install the regulator.

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Page last updated: Sat 12/3/2016 02:35:40 AM