Fuel pressure regulator
The biggest problem on the early stage of the engine was the fuel pressure regulator, which is responsible for maintaining the appropriate pressure in the injection rail according to the assumed curve, depending on the engine speed and load. Unfortunately, most regulators have a factory defect, which often caused the regulator to jam, which also resulted in an emergency engine shutdown.
The reason is the use of thermoplastic material, which loses its original properties over time under the influence of high temperature and gasoline. In addition, there is a deposit of fuel depositing on the walls, which with time hinders the movement of the regulator piston (the gap between the piston and the sleeve is 0.05 mm). There are known cases where the regulators were replaced many times, fortunately under the warranty. In addition, these regulators could overload the high pressure pumps, resulting in burst of the diaphragms
The problem was only solved in 2009, when Opel introduced a modified version of the regulator. The modified regulators have the designation from 266 09 (see the picture)
The all regulators can now be overhailud. This extends the mechanical life to approx. 100-150 thousand km. Regulators can also be purchased on the secondary market, but it carries a high risk, because many damaged regulators are sold by people who have acquired new ones, and those coming from disassembly may stop working properly in a moment.
The regulators are also overhailued by Opel, then they have a white sticker (see the picture)
Disassembly and assembly
Very important ! The regulator may only be removed when the engine is cold. You should also have a fire extinguisher nearby, just in case. Attempting to remove it while the engine is hot may result in fire. The fuel is under high pressure and temperature of approx. 100 ° C. Unsealing of such a system leads to the immediate boiling of gasoline and its discharge outside, which may cause ignition and explosion of vapors or burns
- Disconnect the battery (negative terminal)
- Remove the engine cover
- Unscrew 2x bolts
- Pull out the regulator
- Lubricate o-rings with grease
- Replace 2x seal rings (7,5x,1,5 FPM and 12x1,5 FPM)
- Tighten 2x bolt 8 Nm
- Connect and lock wiring harness plug
- Connect the battery
F5R fuel pressure regulator
The fuel pressure regulator from F5R Team. The regulator F5R Team (UE116120EAF) has been manufactured from the high quality materials ensuring long term trouble-free operation (valve made of tungsten carbide).