Potential Fuel Pressure Regulator Solution

[Jagdpanzer]

Here are photos of the steps I used for adapting the Delphi FP10016 fuel pressure regulator to the original LT5 fuel pressure regulator base:
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Machining off the old cap

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IMG_1074.JPG
Failed regulator had a ruptured diaphragm

IMG_1080.JPG
Drilling hole in base for pressing out old hardened valve seat

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Pressing out old valve seat




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[Jagdpanzer]

Base internal machining


Fabing retainer ring


Threading retainer ring screw holes in base


Parts laid out ready for assembly

[Jagdpanzer]

Plug in base installed


O-ring seals installed


Regulator inserted in base


Retainer ring attached


Finished!

[-=Jeff=-]

You need to start an exchange program.. minimize downtime for those interested

[secondchance]

That's so Industrial Age chic.

[Ccmano]

Appears somewhat labor intensive Phil. Once the process is sorted out what do you think the time per unit will be? Will you do it yourself or farm it out?
H

[Jagdpanzer]

My lathe and mill are simple manual machines so set up time between steps consumes more time than I like at my leisurely pace. Was able reduce the time to turn out the retainer ring to 30 min. Rest of the machine work, cleanup, and assembly takes about 2 hours.
Producing several at one time I’m sure would improve efficiency.


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[Scrrem]

Very nice work Phil!
Rich

[Dynomite]

Fuel Pressure Accelerating and on Cruise.
(Engine in Full Power Setting for all tests) A 1995 ZR-1 with Stock FPR and a 1990 with IFPR were tested with identical results.



No issues........no stumbling in any gear and very smooth in cruise.

A. Cruising in 1st-5th at speeds up to 60mph resulted in Fuel Pressure of 42 psi except when decelerating pressure dropped to 38 psi.
B. Accelerating in all speeds resulted in Fuel Pressure increasing smoothly to 48 psi while accelerating only then the pressure backed down to 42 psi while cruising.
C. At FULL Throttle the Fuel Pressure spiked at 52 psi in all gears.
[B]D. Cruising at 80 mph in 6th gear resulted in Fuel Pressure stabilized at 43 psi just a tad above idle pressure of 42 psi

This is identical to what BlackZR1 experienced while testing Fuel Pressure while Driving.

Originally Posted by BlackZR1

With the extension hose and pressure gage on the dash I went for a drive. I expected that as fuel demand goes up there would be step change in pressure when the secondary pump came on. Instead, what I saw was that at idle the pressure sat at 42 psi and as I stepped on the gas pedal regardless of engine or car speed the pressure would rise smoothly and proportionate to the gas pedal. Pressure rises to 52psi by the time the pedal was about ½ way down. Any momentary or sustained WOT resulted in a 52psi pressure. So all is good.

Short roundtrip to Fresno (100 miles).....No issues and no stumbling in any gear and very smooth in cruise.
Getting 27mpg - 28mpg in sixth gear going 70mph which was identical to mileage using Stock Unmodified FPR which indicates the IFPR behaves exactly like a Stock FPR that BlackZR1 Tested While Driving with various Throttle Positions.

1990 LT5 and 1995 LT5


Post 281 - The Improved LT5 Fuel Pressure Regulator

[XfireZ51]

Out of curiosity, have u pulled any of the spark plugs?