Volkswagen Parts Catalog Volkswagen Accessories Catalog Volkswagen Tech Information Volkswagen Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Fuel Pressure Regulator Replacement

Jared Fenton

Time:

1 hour1 hr

Tab:

$45

Talent:

***

Tools:

Large flathead screwdriver, silicone grease

Applicable Models:

Jetta MkIV 2.0L (1999-05)

Parts Required:

Fuel pressure regulator

Hot Tip:

Wait until the engine is cold to replace.

Performance Gain:

Better running engine

Complementary Modification:

Replace fuel filter

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 or under vacuum.

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 50psi) and that all connections to the gauge are correct. See our article on Checking Fuel Pressure for more information.

Turn the key on and off several times to energize the fuel pump. This will build up pressure in the fuel rail and begin to register on the gauge. The system operating pressure is 35-40psi. If the operating pressure is below 35psi or fluctuates wildly, it is probably a good bet that the regulator is bad. If you pull off the vacuum connection and there is fuel dribbling from the nipple, the diaphragm inside has failed and the regulator must be replaced (this was the case on our project car).

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.

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 (yellow arrow) 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 back in place.

Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Sat 12/3/2016 03:10:11 AM