The 2002 Tahoe came standard with a 275-horsepower, 4.8-liter V-8 engine. As the load on the engine increases from idle, the engine requires additional fuel to run correctly. The fuel pump delivers between 55 and 62 psi of fuel pressure to the regulator, which raises and lowers the fuel pressure delivered to the fuel injectors, using the vacuum created by the engine. As the vacuum decreases because of increased engine load, the regulator allows more fuel pressure and vice versa. Replacing the fuel pressure regulator on the base 2002 Tahoe is a straightforward task, but you need to relieve the fuel pressure first.
Install a memory saver onto the vehicle in accordance with the memory saver’s instruction manual. Loosen the negative battery cable terminal retaining bolt, using a combination wrench, and pull the negative cable from the battery. Position the cable aside to prevent accidental reconnection.
Loosen the bolt securing the engine cover, using a ratchet and socket. Lift the front of the cover upward, then pull it from its bracket. Remove the cover from the engine compartment.
Unscrew the gas cap and set it aside. Find the fuel rail crossover pipe -- the pipe that connects the left side of the fuel rail to the right side. Look on the driver’s side, rear of the crossover pipe and find the fuel pressure Schrader valve. Insert a small flat-head screwdriver into the Schrader valve so it lightly contacts the small pin inside the valve. Wrap the flat-head screwdriver in a thick shop cloth and press the screwdriver into the valve to relieve the fuel system pressure. Remove the cloth and screwdriver.
Trace the passenger’s side fuel rail rearward until you find the fuel pressure regulator. Pull upward on the pressure regulator’s vacuum cable, using a twisting motion, to remove it. Wipe any dirt and debris from around the fuel pressure regulator with a shop cloth.
Grip the fuel pressure regulator saddle clip, the U-shaped metal clip with a slot cut in the center, with slip-joint pliers and pull it upward while prying one side of the clip outward with a small flat-head screwdriver to remove it.
Pull the regulator from the fuel rail, using a slight twisting motion.
Compare the saddle clip you removed from the failed pressure regulator to the one that came with the new regulator. Verify that the tabs on the clips match perfectly, as there are three different setups for the 2002 Tahoe. If they do not match perfectly exchange the pressure regulator for the correct one.
Apply a thin coat of new engine oil to the new regulator’s O-rings. Guide the new regulator into the fuel rail with its vacuum inlet facing upward. Hold pressure on the regulator toward the fuel rail and slide the new saddle clip over the flanges connecting the regulator to the fuel rail, press the clip downward until it snaps into place.
Connect the vacuum line to the regulator’s inlet. Tighten the gas gap until you hear it click.
Reconnect the negative battery cable and tighten its retaining bolt to 13 foot-pounds, using a torque wrench and socket.
Turn the ignition to the “Run” position and leave it in place for about two seconds. Turn the key to the “Off” position and leave it there for 10 seconds. Turn the key to the “Run” position and check around the regulator for leaks.
Guide the rear of the engine cover into the bracket’s hooks and tighten its retaining bolt to 89 inch-pounds, using an inch-pound torque wrench and socket.
