Fuel pressure regulator - removal and refitting
Caution: Refer to the precautions in Section 1 before proceeding.
2.0 litre SOHC models
1 Disconnect the battery negative lead.
2 Slowly loosen the fuel feed union to relieve the pressure in the fuel lines.
3 Disconnect the fuel feed and return lines.
Be prepared for petrol spillage.
4 Disconnect the vacuum pipe from the top of the pressure regulator.
5 Unscrew the securing nut from the base of the pressure regulator and withdraw the unit (see illustration).
6.5 Withdrawing the fuel pressure regulator
6 Refitting is a reversal of removal, but if the fuel return line was originally secured with a crimped type clip, discard this and use a new worm drive clip.
7 On completion check the fuel line connections for leaks. Pressurise the system by switching the ignition on and off several times.
2.0 litre DOHC models
Note: A new pressure regulator seal will be required on refitting.
8 Disconnect the battery negative lead.
9 Slowly loosen the fuel rail fuel feed union to relieve the pressure in the system (see illustration). Be prepared for fuel spillage, and take adequate fire precautions.
6.9 Fuel rail fuel feed union (arrowed)
10 Disconnect the fuel return hose from the pressure regulator (see illustration). Again, be prepared for fuel spillage.
6.10 Disconnecting the fuel return hose (arrowed) from the pressure regulator
11 Disconnect the vacuum pipe from the top of the pressure regulator.
12 Unscrew the two securing bolts, and withdraw the regulator from the fuel rail.
Recover the seal.
13 Fit a new seal to the regulator, and lubricate with clean engine oil.
14 Fit both the securing bolts to the regulator, then position the regulator on the fuel rail, and tighten the securing bolts.
15 Further refitting is a reversal of removal. If the fuel return line was originally secured with a crimped-type clip, discard this, and use a new worm-drive clip.
16 On completion, pressurise the system by switching the ignition on and off several times, and check the fuel line connections for leaks.
1.6 and 1.8 litre (R6A type) CVH
Note: On completion of refitting, the fuel system pressure should be checked by a Ford dealer at the earliest opportunity.
17 Remove the CFI unit.
18 Remove the four screws securing the regulator housing to the CFI unit, then carefully lift off the housing and recover the ball, cup, large spring, diaphragm, valve, and small spring, noting the position and orientation of all components (see illustration). Do not attempt to prise the plug from the regulator housing, or adjust the Allen screw (if no plug is fitted); this will alter the fuel system pressure.
6.18 Exploded view of Central Fuel Injection (CFI) unit 1.6 litre CVH engine application shown - 1.8 litre similar
1 Fuel injector assembly
2 Fuel pressure regulator components
3 Fuel inlet connector
4 Air charge temperature (ACT) sensor 5 Throttle valve control motor 6 Throttle position sensor 7 Fuel injector wiring
19 Check all components, and renew any faulty items as necessary.
20 Commence reassembly by supporting the CFI unit on its side, so that the regulator components can be fitted from above.
21 Fit the small spring, valve, diaphragm (ensuring that it locates correctly), large spring, and the spring cup.
22 Carefully place the ball into position on the spring cup, and ensure that it locates correctly.
23 Refit the regulator housing, taking great care to avoid disturbing the ball, and once correctly in position, tighten the screws evenly to avoid distorting the diaphragm.
24 Refit the CFI unit.
25 On completion, the fuel system pressure should be checked by a Ford dealer at the earliest opportunity.
26 Disconnect the battery negative lead.
27 Remove the air cleaner assembly.
28 Depressurise the fuel system and disconnect the fuel inlet pipe from the CFI unit (see illustration).
6.28 Fuel injector/pressure regulator attachments - 1.8 litre (R6A) CVH
A Pressure regulator assembly
B Fuel inlet pipe
C Injector/regulator wiring plug D Injector/regulator screws
29 Disconnect the fuel injector/regulator wiring plug, and move the wiring harness clear.
30 Undo the four screws, and carefully lift the injector/regulator assembly off the CFI unit.
31 Refitting is a reversal of removal. On completion, the fuel system pressure should be checked by a Ford dealer at the earliest opportunity.
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