Fuel Pressure Regulator

This procedure covers the replacement of the fuel pressure regulator on the 2015-2020 Ford F-150 3.5L EcoBoost engine, typically mounted on or near the fuel rail assembly.

Warnings

Tools required

Parts

• Fuel pressure regulator × 1 — Use OEM specification
• Fuel pressure regulator O-rings × 1 — Usually included with regulator
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure engine is completely cool to the touch
3. Disconnect negative battery cable and wait 2 minutes for system capacitors to discharge
4. Remove engine cover by pulling upward on cover to release retaining grommets
5. Place drain pan and shop towels under fuel rail area to catch fuel spillage

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pressure test port on the fuel rail (driver side). Remove the Schrader valve cap. Using a fuel pressure gauge or suitable bleed tool, slowly depress the Schrader valve core to release fuel pressure into drain pan. Continue until no more fuel is expelled and pressure gauge reads zero. Replace Schrader valve cap.
   ⚠️Fuel will spray from the Schrader valve. Keep face and body clear of the valve opening.
2. 2

   Remove engine appearance covers if needed
   On some configurations, additional plastic covers may be present over the fuel rail area. Remove any cover screws retaining upper engine covers and set covers aside.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
3. 3

   Disconnect electrical connector from fuel pressure regulator
   Locate the fuel pressure regulator electrical connector on the passenger side of the fuel rail. Press the connector tab and pull the connector straight off the regulator. Secure connector away from work area.
4. 4

   Disconnect vacuum line if equipped
   Some fuel pressure regulators have a vacuum reference line. If present, carefully disconnect the vacuum line from the regulator by releasing the retaining clip or pulling firmly. Note orientation for reinstallation.
5. 5

   Disconnect fuel feed line
   Using the appropriate fuel line disconnect tool, release the quick-connect fitting on the fuel feed line connected to the fuel rail. Push the tool onto the line until it releases, then pull the line away from the rail. Cap the line with a clean shop towel to prevent contamination.
   ⚠Residual fuel will drain from the line. Position drain pan to catch spillage.
6. 6

   Remove fuel rail mounting bolts
   Locate the fuel rail mounting bolts (typically 4 bolts securing the fuel rail to the intake manifold). Remove these bolts in a cross-pattern sequence. Carefully lift the fuel rail assembly up slightly to access the fuel pressure regulator. The rail does not need to be completely removed unless required for regulator access on your specific build date.
   Torque spec

   Fuel Rail Bolts23 Nm (17 lb-ft)
7. 7

   Remove fuel pressure regulator mounting screws
   Locate the fuel pressure regulator mounting screws (typically 2-3 small screws). Remove these screws and carefully pull the regulator away from the fuel rail. Note the orientation of any O-rings or seals.
   ⚠Additional fuel may drain from the regulator housing. Have shop towels ready.
   Torque spec

   Regulator Mounting Screws5 Nm (4 lb-ft)
8. 8

   Remove and inspect O-rings
   Remove all O-rings from the fuel pressure regulator mounting location and the regulator itself. Inspect the mating surfaces on the fuel rail for damage, corrosion, or debris. Clean the mounting surface thoroughly with a lint-free shop towel.
9. 9

   Install new fuel pressure regulator
   Lubricate new O-rings with a small amount of clean engine oil. Install new O-rings onto the new fuel pressure regulator. Carefully align the regulator with the mounting location on the fuel rail, ensuring proper orientation based on electrical connector and vacuum line positions. Hand-start the mounting screws.
10. 10

    Torque regulator mounting screws
    Using a torque wrench, tighten the fuel pressure regulator mounting screws in a cross-pattern to specification. Do not over-tighten as this can damage the regulator body or strip the soft mounting threads.
    Torque spec

    Regulator Mounting Screws5 Nm (4 lb-ft)
11. 11

    Reinstall fuel rail assembly
    If the fuel rail was lifted or removed, carefully lower it back onto the mounting points. Install the fuel rail mounting bolts and tighten in a cross-pattern to specification using a torque wrench.
    Torque spec

    Fuel Rail Bolts23 Nm (17 lb-ft)
12. 12

    Reconnect fuel feed line
    Inspect the fuel line quick-connect fitting for damage. Install new O-rings if required. Push the fuel feed line firmly onto the fuel rail connection until you hear and feel a positive click. Gently pull on the line to verify it is securely locked.
13. 13

    Reconnect electrical and vacuum connections
    Reconnect the fuel pressure regulator electrical connector until it clicks into place. If equipped, reconnect the vacuum reference line and secure with the retaining clip.
14. 14

    Reconnect battery and prime fuel system
    Reconnect the negative battery cable. Turn the ignition key to the ON position (do not start engine) for 5 seconds, then OFF. Repeat this cycle 3-4 times to prime the fuel system and pressurize the fuel rail. Inspect all connections for fuel leaks.
    ⚠️If any fuel leaks are detected, immediately turn off ignition and relieve fuel pressure. Do not attempt to start the engine.

Reassembly

1. Reinstall all engine covers and secure with cover screws torqued to specification
2. Wipe down all surfaces to remove any spilled fuel
3. Dispose of fuel-soaked shop towels in approved safety container

Verification

• Start the engine and allow it to idle for 2 minutes while monitoring for fuel leaks around the regulator and all connections
• Check for proper fuel pressure using a fuel pressure gauge (should be 55-65 PSI at idle for 3.5L EcoBoost)
• Listen for smooth engine operation with no fuel starvation symptoms
• Verify no check engine light or fuel system codes are present using a scan tool
• Test drive the vehicle and verify normal acceleration and no fuel delivery issues under load

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