Fuel pressure REGULATOR - R.R.

Operation 1060E50 · Diesel pressure pump

Removing

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal.

1. Disconnect the electrical connection from the air flow meter.

2. Loosen the band and disconnect the the turbocharger air inlet sleeve from the rigid pipe, air flow meter side.

Always ensure everything is clean whilst removing-refitting the pressure regulator.

1. Loosen the band (1a) and disconnect the flexible hose (1b) from the air intake.

2. Remove the air filter (2a) complete with air flow meter (2b) by releasing from the underlying pins and then from the rear fastening.

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the stop OFF, then disconnect the battery negative terminal.

Proceed with the removal - 7055B54 under-engine guard - r r.

1. Undo the bolts (1a) and move aside the fuel return manifold pipe (1b) without disconnecting the pipes.

1. Disconnect the electrical connection from the fuel pressure regulator.

Position something suitable under the regulator to collect any components which could drop during the stages which follow.

2. Undo the bolts (2a) securing the fuel pressure regulator (2b) to the single fuel manifold pipe.

Never grip the pressure regulator by the electrical connector.

Grip the outer casing of the regulator, partly extract it and, at the same time, turn it so that the fins in which the openings for the fixing bolts are located are positioned horizontally, then insert the blades of two screwdrivers by the fins and very carefully extract the pressure regulator.

Do not use screwdrivers or other tools in the areas between the pressure regulator and single fuel manifold pipe.

Remove the gasket between pressure regulator and single fuel manifold pipe.

Position a suitable container beneath the regulator to collect any components which could drop during the stages which follow.

1. Disconnect the electrical connection from the fuel pressure regulator.

2. Undo the bolts fixing the pressure regulator to the pump without removing.

1. After removing the regulator, check that the high-pressure seal (1a) (black or green) and anti-extrusion sealing ring (1b) (white) are present.

If one of the sealing rings has been accidentally left inside the single fuel manifold pipe, turn the ignition on (engine off); in this way the presure pump shaft will be operated and a small amount of fuel and the sealing ring will come out. Do not, under any circumstances, use any tools to extract the sealing ring, as this could damage the inner surface of the single fuel manifold pipe.

1. Grasp the outer case of regulator (1a), remove partly and turn simultaneously to position tabs (1b) containing holes for retaining bolts horizontally.

Never grip the pressure regulator by the electrical connector.

2. Insert the blades of two screwdrivers by the fins (1a - Fig. 9) and, working very carefully simultaneously with the two screwdrivers, extract through pressure regulator using an axial movement.

Do not use screwdrivers or other tools in the area between the regulator and the pressure pump.

Refitting

Suction off any impurities in the single fuel manifold pipe.

Before fitting, check the condition of the two sealing rings and make sure they are correctly positioned.

Lubricate the outer surface of the two seals for the pressure regulator using Vaseline.

Do not, under any circumstances, lubricate the other surfaces of the pressure regulator.

Fit a new gasket between pressure regulator and single fuel manifold pipe.

Fit the pressure regulator in its seating, pressing gently and at the same time rotating the regulator until it is in contact with the surface of the single fuel manifold pipe.

Do not, under any circumstances, use a hammer or other tools for fitting the pressure regulator in position.

Tighten to the specified torque the bolts securing the fuel pressure regulator to the single fuel manifold pipe.

The above bolts cannot be tightened using a torque wrench; as a guide, tighten to a torque of 0.8 1.0 daNm

Connect the electrical connection to the fuel pressure regulator.

Refit the air filter complete with air flow meter, engaging it in the rear attachment and then in the underlying pins.

Connect the flexible hose to the air intake on the crossmember and tighten the fixing band.

Connect the air intake sleeve to the turbocharger, air flow meter side, and tighten the band.

Connect the electrical connection to the air flow meter.

Connect the battery negative terminal.

Ensure that the ignition key is in position - Connect the negative battery terminal.

1. After having removed the regulator, check that the high pressure seal (black or green), the anti-extrusion seal (1b) (white) and the low pressure seal (1c) (black) are present.

If the high pressure seal or any of the other seals have accidentally remained inside the pump casing, turn the ignition key to the ON position (with the engine switched off); a small amount of fuel will emerge with the seal.

Do not, under any circumstances, use any tools to extract the seals as this could damage the inner surface of the pump.

Refitting

Suction off any impurities inside the pump casing.

Before fitting, check the condition of the three seals and the new regulator and make sure they are correctly positioned.

Lubricate the outer surface of the three seals using vaseline.

Do not, under any circumstances, lubricate the other surfaces of the pressure regulator.

Fit the pressure regulator in its housing on the pump, pressing gently and, at the same time, rotating the regulator until it is in contact with the surface of the pump.

Do not, under any circumstances, use a hammer or other tools for fitting the pressure regulator in position.m

Tighten the pressure regulator retaining bolts.

The above bolts cannot be tightened using a torque wrench. As a guide, tighten to a torque of 0.8 1.0 daNm

Connect the electrical connection to the fuel pressure regulator.

Place the fuel return manifold pipe back in its housing and secure it using the bolts.

Proceed with the refitting - 7055B54 under-engine guard - r r.

Connect the battery terminal (-).

Remove the car from the ramp.