Installing Turbosmart Fuel Pressure Regulator: A Step-By-Step Guide

Installing a Turbosmart fuel pressure regulator is a potentially hazardous task that can cause serious engine damage or personal injury if done incorrectly. It is recommended that the regulator is fitted by a qualified technician. The process involves securing the mounting bracket to the main unit, remote mounting the FPR, and ensuring that all plumbing is appropriately secured and the correct size. Prior to mounting the FPR, it is important to install fittings into the FPR with high-quality AN ORB fittings, ensuring the O-ring is present. After installation, it is crucial to check for any leaks in the fuel system and ensure fuel suitability.

Prepare FPR for installation

Before mounting the FPR, there are a few steps to take to ensure it is prepared for installation. Firstly, install the fittings into the FPR with high-quality AN ORB fittings, ensuring that the O-Ring is present. You can use an optional Turbosmart fitting kit, such as the TS-0402-11XX (NPT, -6 to -10 AN). It is important to note that flare fittings cannot be used internally on the FPR; they must be ORB internally.

The next step is optional. If you wish to install a 1/8” NPT gauge or sensor, now is the time to do so. First, unscrew the existing 1/8” NPT blank anti-clockwise with a 3/16” hex key. Then, apply thread lubricant and screw it in clockwise until finger-tight. Finally, tighten it further by 1-2 turns to ensure a good seal. You can use a Turbosmart gauge kit, such as the TS-0402-2023, for this step.

O-rings are not used in the FPR Kompact (1/8” NPT) due to the tapered thread, so a fuel-safe thread lubricant should be used instead.

With all the fittings installed onto the FPR, you can now move on to the mounting process.

Fit gauge or sensor port

Installing a gauge or sensor port is an optional step in the installation of a Turbosmart fuel pressure regulator. This step should be carried out prior to mounting the FPR.

First, you need to install a 1/8” NPT gauge or sensor. Unscrew the existing 1/8” NPT blank anti-clockwise with a 3/16” hex key. Apply thread lubricant to the new gauge or sensor and screw it in clockwise until finger-tight. Then, tighten it further by 1-2 turns to seal it. A fuel-safe thread lubricant should be used. Turbosmart offers an optional gauge kit (TS-0402-2023).

It is important to note that O-rings are not used in the FPR Kompact (1/8” NPT) due to its tapered thread.

After installing the gauge or sensor port, the FPR can be mounted. The mounting bracket is held on with two M5 Allen key screws. A 3mm Allen key is required to mount these to the back of the FPR.

Mount the FPR

To mount the FPR, you will need to decide on a location that is secure and accessible. Some options include the strut tower or the firewall next to the master cylinder. You can also install it inline with the fuel filter. If you are mounting it on the strut tower, make sure there is enough clearance between the intake and the tower. If you are installing a fuel pressure gauge, you may need to fabricate a mount to secure it in place.

When you have decided on a location, you will need to prepare the surface. This may involve cleaning or painting the area to ensure that your FPR is installed on a clean, rust-free surface.

Next, you will need to assemble the FPR according to the manufacturer's instructions. This may involve attaching an adapter or bracket to the FPR. Carefully handle the FPR and avoid damaging any components.

Once the FPR is assembled, you can position it in the desired location and mark the mounting holes. Drill the holes carefully, ensuring they are straight and the correct size. You can then secure the FPR in place using bolts or other appropriate fasteners.

Finally, you will need to connect the FPR to the fuel lines. Cut the fuel line carefully and insert the FPR inline, ensuring that all connections are tight and secure. Be careful not to strip any screws or damage the fuel lines during installation.

Connect fuel lines

Now that you have prepared the FPR for installation, you can proceed to connect your fuel lines. First, you will need to remove the fuel pressure from your fuel lines. This can be done by removing the fuel cap and pulling the fuel pump fuse, then cranking the car. Alternatively, some repair manuals may instruct you to crank the car, then remove the fuel pump fuse and wait for the car to stall and turn off. Either way, depressurise the lines.

Next, remove your old FPR. This is usually located at the front near the fuel rail. It is typically held by two screws, so use a properly-sized screwdriver or ratchet to avoid damaging them. Remove the fuel hose by loosening the clamps and pulling out the old FPR upwards and away from the fuel rail. A small amount of fuel may spill out from the fuel rail. Once the old FPR is removed, you will notice it has a rubber O-ring. This should be replaced to prevent leakage.

Now, pull the FPR from the fuel return line. This is where it can get messy, as fuel may spill out. Remove the hose and start test-fitting the new FPR. Decide where you want to mount the FPR and test how the gauge will fit. You may need to create a bracket to bolt on the FPR to the engine. Once you have finalised the fuel lines plumbing, you can start to connect the fuel lines.

The TS fuel rail adaptor comes with an O-ring and a 1/8 NPT port. Place a 90-degree fitting on the NPT port and connect this to the corresponding port on the FPR with another 90-degree fitting. Then, run a straight fitting from the FPR back to the factory fuel line that connects to the fuel tank. Refer to your FPR manual to identify the fuel IN/OUT ports. On the TS unit, the fuel rail port is on the side while the return is on the bottom of the unit.

After building your bracket, sand and paint it with high-temp paint to clean it up. Then, put the fittings on the FPR permanently. Use liquid thread sealant and let it cure overnight. Finally, connect the vacuum hose from the manifold to the FPR and start the car to check for leaks.

Check for leaks

After installing your Turbosmart Fuel Pressure Regulator, it is crucial to check for any fuel leaks. Even a small leak can have serious consequences, including engine damage or personal injury. Here are the detailed steps to ensure your safety and the proper functioning of your vehicle:

Firstly, before starting the engine, thoroughly inspect all fittings, lines, and mountings. Ensure that everything is securely connected and there are no apparent signs of leakage. This initial inspection is a critical safety measure. If you notice any issues, rectify them immediately and do not proceed until you are confident that everything is secure.

Once you have visually inspected the relevant components, you can initiate the engine. During this process, remain vigilant for any signs of fuel leaks. If you detect a leak, shut down the engine immediately. Do not operate the vehicle until the leak has been addressed and resolved. This immediate response is crucial to prevent potential hazards.

In the event of a fuel leak, carefully examine the fittings and O-rings. Ensure that the fittings are tight and securely connected. Check the O-rings for any signs of damage, including cracks or wear. If necessary, replace the O-rings with new ones to ensure a proper seal. It is recommended to have spare O-rings on hand for such situations.

After addressing any leaks, restart the engine, and once again, maintain a vigilant watch for any signs of fuel leaks. This second check is to ensure that your previous rectifications were successful and that there are no remaining issues. If, after addressing the initial leak, you discover a new leak, repeat the process of shutting down the engine and inspecting the fittings and O-rings.

Finally, consult the Turbosmart instructions for additional troubleshooting steps if you continue to experience issues with fuel leaks or other problems. These steps will provide detailed guidance on further actions to take. Remember that incorrect installation or adjustments can lead to hazardous situations, so it is always best to proceed with caution and seek professional assistance if needed.

Frequently asked questions