Tomei Fuel Pressure Regulator: Installation Guide

Installing a fuel pressure regulator (FPR) is a relatively straightforward process, but it's important to take the necessary precautions when working with fuel to avoid any fire hazards. The Tomei FPR is designed to be used with a larger fuel pump and injectors to provide the correct fuel pressure flow when tuning engines. The installation process involves removing the fuel from the fuel lines, disconnecting the car battery's negative terminal, and disconnecting the vacuum hose from the regulator before removing the old regulator. It is crucial to have the correct car manufacturer's maintenance manual for reference and to ensure that all fittings and connections are secure to prevent fuel leakages. The new FPR can then be mounted using a bracket and connecting the fuel piping connections. It is important to refer to the FPR manual to identify the fuel IN/OUT ports and ensure proper installation. Additionally, the pressure can be adjusted by loosening the lock nut and turning the bolt to achieve the desired fuel pressure.

Disconnect the car battery's negative terminal

Disconnecting the car battery's negative terminal is an important step when installing a Tomei Fuel Pressure Regulator, or any time you are working on a car's electrical system. Here is a detailed guide on how to do this safely and effectively:

First and foremost, locate the car battery. It is usually located in the engine bay, but can sometimes be found in the trunk or under a seat. Once you have located the battery, identify the negative terminal. It will be clearly marked with a "-" symbol or a black cover. Before proceeding, make sure you have the appropriate tools, such as a socket wrench or adjustable spanner, and safety equipment, including gloves and eye protection.

Next, loosen the nut or bolt that secures the negative battery cable to the terminal. You may need to wiggle the cable slightly to remove it from the terminal. Be careful not to let the cable touch any metal parts of the car, as this could cause a short circuit. If the cable is stuck, you can apply a small amount of penetrating oil or spray lubricant to the connection and wait a few minutes before trying again.

Once the cable is loose, carefully disconnect it from the battery terminal. Again, be mindful of any metal surfaces that the cable could come into contact with. Set the cable aside, ensuring it is away from the battery and any metal components. At this point, you may also want to cover the terminal with a piece of electrical tape or a terminal cover to prevent accidental contact.

With the negative terminal disconnected, you can now safely work on the car's electrical system without risking a short circuit or electrical discharge. It is important to keep the area around the battery clear and ensure that the negative cable does not come into contact with any metal parts during the rest of your work.

When you have completed your repairs or installations, you can reconnect the negative battery cable. Simply align the cable with the negative terminal and tighten the nut or bolt securely. Make sure that the connection is firm and that the cable cannot be easily pulled away from the terminal. Finally, remove any tape or covers from the terminal, and you're done!

Disconnect the vacuum hose from the regulator

Disconnecting the vacuum hose from the regulator is a crucial step in installing a Tomei fuel pressure regulator. This process requires careful attention to detail and a methodical approach to ensure a safe and successful outcome. Here is a step-by-step guide to help you navigate through this procedure:

Firstly, it is imperative to prioritize safety. Before beginning any work, ensure you have the correct car manufacturer's maintenance manual for reference. It is also recommended to work in a well-ventilated area, away from fire hazards such as welding equipment or electric motors. The presence of fuel vapors in the room poses a fire hazard, so adequate ventilation is essential.

Now, let's delve into the specific steps for disconnecting the vacuum hose:

• Disconnect the car battery's negative terminal. This step is crucial for safety and should always be performed before proceeding with any automotive maintenance or repair work.
• Identify the vacuum hose: Locate the vacuum hose that is connected to the regulator. It is typically attached to the regulator and the intake manifold.
• Carefully remove the vacuum hose: Using the appropriate tools, carefully disconnect the vacuum hose from the regulator. It is important to be gentle and deliberate in this step to avoid any damage to the hose or the regulator.
• Absorb any fuel spills: As you remove the vacuum hose, there may be some fuel spillage. Use rags or other absorbent materials to catch and control the spread of fuel. It is important to work over a drip pan or a clean surface to contain any spills effectively.
• Set aside the vacuum hose: Once the hose is disconnected, set it aside in a safe place. Ensure that it is away from the work area to prevent any accidental damage or interference during the rest of the installation process.
• Check for leaks: Before proceeding further, it is crucial to inspect the regulator and the hose for any signs of fuel leaks. Pay close attention to the connection points and the surrounding areas. If any leaks are detected, address them immediately and ensure a proper seal before continuing.
• Prepare for the next steps: With the vacuum hose successfully disconnected and no leaks detected, you can now move forward with the rest of the installation process for your Tomei fuel pressure regulator. Refer to your specific vehicle's maintenance manual and the Tomei installation manual for further instructions.

Remember, working with fuel-related components carries a high risk of fire. Therefore, it is imperative to exercise caution, follow safety guidelines, and have a fire extinguisher nearby during the entire process.

Remove the old regulator

To remove the old regulator, start by removing the fuel from the fuel lines. It is important to work in a well-ventilated area and disconnect the car battery's negative terminal before beginning any work. Next, disconnect the vacuum hose from the regulator. Be careful when removing the screws holding the old regulator in place, using a properly sized screwdriver or ratchet to avoid damaging them. Once the screws are removed, carefully loosen the fuel hose clamps and remove the old regulator upwards and away from the fuel rail. There may be a small amount of fuel spillage during this process. Finally, pull the regulator from the fuel return line, being prepared for potential messiness as fuel may leak out. It is important to refer to your vehicle's maintenance manual and follow all safety precautions when performing these steps.

Test fit the new regulator

Now, test fit the new regulator. You may want to place it as close to the stock location as possible. Test fit the regulator and gauge, and rig it so you can test-close the bonnet/hood. It is important to ensure that the bonnet/hood closes properly—you don't want to finish your project only to find that something is obstructing the bonnet/hood!

After some trial and error, you may find that you need to make a bracket to bolt the regulator to the engine. You could make a cardboard prototype to test the placement before finalising the design. Mark the spots where you will need to drill holes to mount the bracket to the car.

Finalise the fuel lines plumbing. Refer to your FPR manual to determine where the fuel IN/OUT ports are. You may need to use some 90-degree fittings to connect the corresponding ports on the FPR. Run a straight fitting from the FPR back to the factory fuel line that connects to the fuel tank.

After building the bracket, you may want to sand and paint it with high-temperature paint to clean it up. You can also put the fittings on the FPR permanently, using liquid thread sealant and letting it cure overnight.

Finalise the fuel lines plumbing

Finalising the fuel lines plumbing is a critical step in installing a Tomei fuel pressure regulator. Here is a detailed guide to help you through the process:

Firstly, it is important to select the appropriate fittings or nipples required for the installation. The Tomei Fuel Pressure Regulator comes with two AN6 and two #8 nipple connectors, which are the most common types of fitments for fuel piping. However, depending on your setup, you may need additional equipment or parts. Make sure you have all the necessary components before proceeding.

Next, you will need to connect the fuel piping connections. Refer to your specific vehicle's repair manual for detailed instructions, as the process may vary slightly depending on the car model. The basic steps involve connecting the fuel rail adapter, which bolts onto the factory fuel rail, and then running the appropriate fuel lines to the regulator. In the example provided, a 90-degree fitting was placed on the NPT port of the fuel rail adapter, connecting it to the corresponding port on the fuel pressure regulator (FPR) using another 90-degree fitting. A straight fitting was then run from the FPR back to the factory fuel line that connects to the fuel tank. It is important to refer to your FPR manual to identify the fuel inlet and outlet ports correctly.

Once the fuel lines are connected, you will need to test for any fuel leaks. This is a critical step to ensure the safety of your vehicle. Check all fittings and connections, and ensure that there are no signs of fuel leakages before starting the engine. The risk of fire is high when working with fuel-related parts, so take extra caution.

After confirming that there are no fuel leaks, you can proceed to adjust the fuel pressure to suit your requirements. This is done by loosening the lock nut and turning the bolt with a hex key to raise or lower the pressure. Refer to your vehicle's repair manual or seek professional advice if you are unsure about the correct fuel pressure settings.

Finally, reconnect the vacuum hose from the manifold to the FPR if you had previously disconnected it. Start the car and ensure that there are still no leaks and that the fuel pressure is stable. If everything looks good, you can clean up and take your car for a test drive to enjoy the improved performance and smoother driving experience.

Frequently asked questions