adding insult to injury

Changing a Fuel Pressure Regulator on hard starting 2000 Chevy Silverado Yourself

I was having a problem with my 2000 Chevrolet Silverado. It was starting hard all the time with the exception of first thing in the morning. The first start of the day would go just fine, but the rest would turn over and over rapidly until I pumped the gas pedal. Then it would start but it would sputter for a little bit. Once or twice it also quit on me when I was slowing down to turn a corner.

I had this issue a few years ago and I paid about $200 to get it fixed. The repair shop replaced the fuel pressure regulator, also known as the fuel flow regulator. I figured I could do it myself and as it turns out it’s relatively cheap and quite easy.

First you need to test if your truck has a broken fuel pressure regulator. To do that you need to run the vehicle for about a minute and then turn it off and remove the vacuum line from the regulator -If fuel leaks out, it needs to be replaced. It’s about the size of a walnut and is located on the drivers side fuel rail for the 5.3 liter v8.

Faulty Fuel Flow Regulator

Here are the steps to replace it yourself.

1. Tools and parts needed: Fire extinguisher, a pair of screwdrivers, and something to take the negative post off your battery. The part I got was about $60 from amazon: BWD Automotive 24027 Pressure Regulator (V08161). (update: I’ve heard most people end up paying around $80 for the part elsewhere)

2. Depressurize the fuel system. Start by removing the gas cap.

3. The pressure isn’t gone yet… now you have to pull the fuel pump relay out engine compartments fuse box. And then start the vehicle until it dies. If it doesn’t quit, you pulled the wrong relay, consult the manual. If you do not do this step, gasoline under 40+ lbs of pressure will spray in your face and on the engine.
Fuel Pump relay

4. Disconnect the negative terminal from the battery. (if you’re studying this photo, maybe this project isn’t for you)
Disconnect battery

5. Remove vacuum line and the clip that is holding the regulator in there. I used a pair of screwdrivers to pop it off. Once removed the regulator should just slide right out. Now the fuel screen/filter may be left behind. My kit came with a new filter.
Regulator removed, filter is still there

6. The parts should come out in this order (pictured is not OEM – I had this replaced once before so yours may look different) Notice I got out the little gasket behind the fuel filter.
Fuel Pressure Regulator Parts


7. Here is a picture of it fully removed.

8. Lube the rubber gaskets supplied with the new Fuel Pressure Regulator with a little engine oil.

9. To replace it, just push the new one in and follow the steps in reverse. It may start hard the first time because it has to build the fuel pressure back up. (Note: you may not need all the bushings supplied)
New part in place

Good luck!