2. Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engines.
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1 PART #25001 LT1 Adjustable Fuel Pressure Regulator, PACKING LIST Before installation, use this check list to make sure all necessary parts have been included. ITEM QTY CHECK PART NUMBER DESCRIPTION Bolt, Allen, 4mmX70X10mm Nut, Hex, 6mmX Housing, Fuel Pressure Regulator Retainer, Fuel Pressure Regulator Shim, Fuel Pressure Regulator Screw, Set, 6mmX1.0X25mm 7. ********* Instructions WARNING: SLP Recommends wearing safety glasses for the complete installation. WARNING: SLP Recommends allowing the vehicle to cool (not running) for five hours before beginning installation. WARNING: Too avoid the chance of electrical shock or damage to your vehicle s electrical system, disconnect both the negative and positive batter leads (in that order) at the battery. INSTALLATION INSTRUCTIONS # Ignition OFF 2. Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to start the engines. 3. Loosen fuel filter cap to relieve tank vapor pressure 4. Connect gauge J or equivalent to fuel pressure valve. Wrap a shop towel around fitting while connecting gauge to avoid spillage. 5. Install bleed hose into an approved container and open valve to bleed system pressure. Fuel connections are now safe for servicing. 6. Drain any fuel remaining in gauge into an approved container. NOTE: It may be necessary to remove the fuel rail assembly for easier access to the fuel pressure regulator. If not, skip to the section below, Fuel Pressure Regulator Assembly Modification. 1/5
2 FUEL RAIL ASSEMBLY REMOVAL Tools and pars required: Fuel line Release Tool Set, GM tool #J37088-A Seal Kit, GM # for the 1996 LT1, # for the LT1 (Recommended for fuel rail assembly is removed) An eight-digit identification number is stamped on the fuel rail assembly. Refer to this model identification number if servicing or part replacement is required. NOTE: WARNING: It is not recommended that the fuel injector or fuel pressure regulator O-ring seals be reused. If they are, they must be wiped clean, thoroughly inspected for damage or wear, re-lubricated, and returned to their original respective position. The upper and lower injector O-ring seals re the same size but are different materials. If replacing the seals, please refer to the service manual. USE EXTREME CAUTIN WHEN WORKING AROUND THE FUEL LINES AND FUEL RAILS 7. Disconnect quick-connect fittings at engine fuel pipes: A. Slide rubber dust covers from quick-connect fittings at engine fuel pipes. B. Grasp both sides of fitting. Twist female connector ¼ turn in each direction to loosen any dirt within fitting. C. Using compressed air, blow dirt out of fitting. D. Choose correct tool from J A tool set for size fitting. Insert tool into female connector, then push/pull inward to release locking tabs. E. Pull connection apart. Clean and Inspect: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radical motion with the pipe end to prevent damage to O-ring sealing surface. Using a clean shop towel, wipe off male pipe end. Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required. 8. Disconnect vacuum line on fuel pressure regulator. On 1993 models, additional vacuum lines may have to be disconnected to gain access to fuel rail and engine fuel pipes. 9. Disconnect electrical harness from routing clips on fuel rail. On 1993 models, remove fuel pipe retaining bolt. 10. Disconnect injector electrical connectors. Identify connectors to their corresponding injectors to assure correct sequential injector firing order after reassembly. Clean: Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner, GM X-30A or equivalent, following package instructions. DO NOT soak fuel rails in liquid cleaning solvent. 11. Disconnect fuel rail attaching bolts and remove fuel rail assembly. Note: Use care in removal to prevent damage to injector electrical connector terminals and the injector spray tips. When removed, support the rail to avoid damaging its components. 2/5
3 FUEL PRESSURE REGULATOR ASSEMBLY REMOVAL 1. On 1994 and 1995 models, remove fuel tube bracket attaching screw (17, fig 3) and bracket (16. fig3). For 1993 vehicles skip to step Remove pressure regulator attaching screw (11). 3. Remove fuel pressure regulator (10) from fuel rail. 4. On 1994 and 1995 models, remove fuel outlet tube retainer clip (13, fig 3) and fuel outlet tube (18, fig 3) from pressure regulator. For 1993 vehicles remove fuel outlet tube (22, fig 2). FUEL PRESSURE REGULATOR ASSEBMLY MODIFICATION 1. Examine pressure regulator inlet O-ring (15) for wear and damage. 2. Examine fuel outlet tube O-ring (13, fig 2; 12, fig 3) for wear damage. Note: *It is not recommended that the fuel system O-ring seals be reused. If they are, they must be wiped clean, thoroughly inspected for damage or wear, and relubricated. The appropriate GM part number for the seal kits are found in the list of recommended tools. *For the actual modification of the fuel pressure regulator, refer to figure Position fuel pressure regulator mounting bracket in soft-jawed vise, being careful not to damage bracket. 4. To remove cap on O.E.M. regulator, a belt sander, bench grinder, or mounted hand sander/grinder should be used. Tape off or plug all openings on regulator, and carefully spin the rolled-over edge of cap against grinding surface. Sand just through the cap evenly and around entirely until the cap comes off. Discard it and remove the remaining flange disc. WARNING: The regulator spring is under some compression, so be careful no to lose the spring when removing the upper housing. It is recommended that safety glasses be worn while doing this. NOTE: Be extremely careful when removing the upper housing so as not to damage the O-ring seal or lower section of the regulator. Do not use heat or any kind of power tools to remove the upper housing as this may result in damage or personal injury. 5. Place provided shim in aluminum housing. 6. Position stock spring on shim. 7. Before installing aluminum housing on stock fuel pressure regulator, inspect stock housing O- ring seal. If wear or damage is evident, the seal must be replaced. 8. Install aluminum housing onto fuel pressure regulator, being sure that the vacuum port is oriented properly with respect to the vacuum line. 9. Loosen jam nut and set screw on regulator housing until housing rests on regulator O-ring. 3/5
4 10. Position retainers on other side of mounting flange (figure1) and hand start Allen screws so as to be sure not to cross thread them. Check to sure that correct vacuum port orientation with respect to the vacuum line has been maintained. 11. Using appropriate Allen Key, tighten screws to 5Nm (44 lb. In.). 12. Adjust set screw until the top of the set screw is ¾ from the top of the SLP housing. Lock set screw in place by tightening jam nut. This will provide an initial fuel pressure setting. MODIFIED FUEL PRESSURE REGULATOR ASSEMBLY INSTALLATION 1. Installation is the reverse of removal. All necessary torque specifications are provided in figures 1 through 3. Lubricate new or reused pressure regulator inlet and fuel outlet tube O-ring with clean engine oil before installing on regulator. WARNING: When installation is complete, you must verify that there are no fuel leaks before driving you vehicle. Turn ignition switch to the ON position for two second, OFF for ten seconds, and back to the ON position. Check for fuel leaks, and repair as necessary. 2. With the vehicle running, adjust fuel pressure. Factory setting is between 41 and 47 psi. 4/5
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