Coupe L4-1.9L DOHC VIN 7 (1994)
CAUTION: Support fuel rail to avoid damaging components, during bench repairs.
NOTE: The fuel pressure regulator can be replaced without removing the fuel rail.
REMOVAL
1.
Remove air intake tube/resonator.
2.
Connect fuel gage bar kit SA9127E (or equivalent) to fuel pressure test port.
3.
Install bleed hose into an approved container and open valve to bleed system pressure. Once pressure is bled, remove gauge from fuel pressure test
port and recap it.
4.
Remove bolt from fuel line clip.
CAUTION: A backup wrench (24 mm or 15/16 in.) must be used to prevent damaging the pressure regulator inlet port and bracket.
5.
Disconnect fuel supply and return lines at fuel and pressure regulator.
6.
Remove pressure regulator attaching screw.
NOTE: Prior to removing the regulator, it may be necessary to remove the fuel supply and fuel rail attachment fasteners for access to the fuel
return line nut.
7.
Remove pressure regulator assembly and plug the pressure regulator port in the fuel rail with a clean shop towel.
NOTE: Do not remove the O-ring retainers located in the fuel pressure regulator outlet. The outlet O-ring should only be replaced if damaged.
WARNING: Any time the fuel system is opened for service, the inlet O-ring seal must be replaced.
8.
Remove fuel inlet O-ring and discard. If it is necessary to replace the outlet O-ring a special brass seal removal and installation tool.
INSTALLATION
1.
Lubricate new fuel inlet and return line O-rings with clean engine oil and install on fuel lines.
NOTE: Prior to installing the regulator, the fuel rail or fuel supply line may require removal for access to the fuel return line.
2.
Lubricate new pressure regulator O-rings with clean engine oil and install on pressure regulator.
3.
Install pressure regulator assembly into fuel rail.
4.
Apply SATURN P/N 21485277 (Loctite 242 or equivalent) to the attachment screw threads. Install the pressure regulator attaching screw.
^ Torque: 12 Nm (106 in lbs)
CAUTION: A backup wrench (24 mm or 15/16 in.) must be used to prevent damaging the pressure regulator inlet port and bracket.
5.
Connect fuel supply and return lines.
^ Torque: Feed: 15 Nm (133 in lbs)
^ Torque: Return: 15 Nm (133 in lbs)
6.
Prime fuel system.
a. Cycle ignition "ON" for 5 seconds and then "OFF" for 10 seconds.
b. Repeat step 6a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds.)
d. If engine does not start, repeat steps 6a - 6c.
7.
With engine "OFF" and ignition "ON", pressurize system and check for fuel leaks.
8.
Install air intake tube and resonator.