This tutorial is also available in French ➔

Fuel pressure regulator refurbishment on Defender Td5

Vehicle ➔ Defender 110 Td5 2002

Difficulty ➔ Medium

Time ➔ 3 hours

Summary

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Remove the capsule from the fuel pressure regulator

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Land Rover spare parts dealers sell the fuel pressure regulator assembled with its hoses. In most cases, only the small capsule of the regulator is faulty and it is simply enough to change it to eliminate the fuel leak. This tip allows you to repair your Defender for much less.

There are a multitude of fuel pressure regulator capsules for sale on the internet. I installed the Bosch capsule 0280160575. This capsule is recommended by internet users on many forums.

The Bosch capsule 0280160575 can be used on the fuel pressure regulator of all Defender Td5 from 1998 to 2006 :
• On the LR016319 regulator (Defender up to year 2001 - up to serial number 1A622423 - up to engine number 10P15967B). This regulator has 2 hoses.
• On the LR016318 regulator (Defender from year 2002 - from serial number 2A622424 - from engine number 10P15968B). This regulator has 3 hoses.
The differences between these 2 regulators are the fuel system, the number of hoses and the gasket. However, the regulation pressure is the same (4 bars).

The Bosch capsule 02280160575 is delivered without any seal and gasket. Remember to order the O-rings (ERR6761 and STC4509) as well as the gasket (MSX100080 for LR016319 regulator or MSX000010 for LR016318 regulator) required for assembly.

Required Tools

Remove the fuel pressure regulator (➔ see the tutorial ''Fuel pressure regulator change on Defender Td5'' Op 01 to 12).

Op 02

Remove the capsule retaining circlip. Use circlip pliers.

Op 03

Remove the capsule. Use multigrip pliers.

Op 04

Thoroughly clean the aluminum body of the fuel pressure regulator.

Fit the new capsule

Op 05

Fit the new capsule (0280160575) on the body of the fuel pressure regulator. Push by hand.

A few drops of fuel on the capsule seals will make it easier to install.

Take extreme care when installing the capsule. You must press hard enough to engage the capsule in the regulator body, but you must not press too hard to avoid damaging the 2 seals on the capsule (personal experience).

Op 06

Fit the capsule retaining circlip. Use circlip pliers.

Change the hoses O-rings

Op 07

Remove the O-ring from the fuel cooler hose. Use a small flathead screwdriver.

Op 08

Remove the O-ring from the rigid fuel pipe. Use a small flathead screwdriver.

Op 09

Fit new O-rings (STC4509) on the fuel cooler hose and on the rigid fuel pipe. Push by hand.

Put a few drops of fuel on the O'rings before installing them.

Op 10

Fit the fuel pressure regulator on the cylinder head (➔ see the tutorial ''Fuel pressure regulator change on Defender Td5'' Op 26 to 41).

The End

The fuel pressure regulator is refurbished. The fuel leak is now just a bad memory.
Please feel free to ask a question or to write a comment at the bottom of the page if you wish.