Fuel pressure REGULATOR - R.R.

Operation 1060E50 · Diesel pressure pump

1.9 JTD 8V · Euro 3

Removing

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1. Undo the bolt (1) fixing the cable loom to the intake manifold.

2. Disconnect the electrical connectors (2) for the injectors.

3. Cut the band (3) retaining the injection wiring.

4. Remove the oil dipstick (4).

1. Undo the bolt (1a) fixing the oil dipstick pipe (1b) to the intake manifold (1c).

2. Open the band (2a) retaining the excess diesel rigid return pipe (2b).

Raise the car.

1. Open the band (1a) and release the wiring (1b) for the rpm sensor and motor/alternator.

2. Undo the bolt (2a) fixing the oil dipstick pipe (2b) to the crankcase.

3. Remove the oil dipstick pipe from underneath.

Lower the vehicle.

1. Undo the nuts (1a) fixing the fuel return manifold pipe (1b) to the inlet manifold and then move it aside.

1. After positioning something suitable for collecting any components that may fall under the regulator during the following stages, prepare a spanner composed of the following USAG components: insert (1a) type: 660TX30; connector (1b) type: 330.1/4; extension (1c) type: 236 1/4; ratchet (1d) type: 237 1/4 SI

1. Disconnect the electrical connector (1a) for the pressure regulator, then undo the bolts (1b) fixing the regulator to the pump.

Never grip the pressure regulator by the electrical connector.

1. Grip the outer casing of the regulator, partly extract it and, at the same time, turn it so that the fins (1a) 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 area between the regulator and the pressure pump.

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 and intact.

If the high pressure seal hase accidentally remained inside the pump casing, turn the ignition key to the ON position (with the engine switched off); the pump shaft will be operated and a small amount of fuel and the seal will come out this way.

Do not, under any circumstances, use any tools to extract the high pressure seal 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 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.

Conect the electrical connection for the pressure regulator.

Position the fuel return manifold pipe and tighten the nuts fixing it to the inlet manifold.

Raise the car.

Position the oil dipstick pipe and tighten the bolt fixing it to the crankcase.

Position the wiring for the rpm sensor and motor/alternator and close the retaining band.

Lower the vehicle.

Position the excess diesel rigid return pipe and close the retaining band.

Tighten the oil dipstick bolts.

Position the oil dipstick.

Fasten a new injection wiring band.

Connect the electrical connections to the injectors.

Tighten the bolt fixing the cable loom to the inlet manifold.

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