just finished rebuilding my fpr and i got about 75-80 psi new oem kit with a new spring made sure spring was not kinked and was seated correctly checked thru the return line hole spring is centered. oiled all orings before installed no leaks just wasnt sure about pressure seems a bit high have they changed the pressure of the new stuff ? my other stock pressure was about 62-67 . i only cycled the key a couple times and drove it in the lot here, getting ready to go home 34 miles. what do you guys think to much pressure?. i used the factory ford part#f81z-9b249-bb early 99 no tuner yet stock fuel pump, good open return line checked while it was off ,as you can see it needed rebuilding it has been intermittently spiking from 62-67 to 100 or more for a couple weeks

 

My pressure was about 3-4 lbs high for a few days and then it settled in at 70 psi at idle. Good call to change yours out because your original parts look pretty rough.

Here are some photos of my original FPR. This is with about 260k miles. Not too dirty but it was still sticking because I would get pressure spikes around 95-100 psi also.

I notice that your original poppet guide is different than mine. Is that an e99 thing? My kit came with a new poppet guide and o-ring but I was not able to use the o-ring, it just wouldn't fit so I had to re-use my original flat seal (labeled as Band Seal in the attached photo...)

Did you have any similar issues or were you able to use the o-ring that came in the kit?

 

By the looks of the gunk that has built up on the poppet, it looks like some pretty dirty fuel has gone through your tank in the past. As long as you are confident that your pressure gauge is accurate, there may be a severe restriction in the return line that is causing backpressure to influence the pressure at the fuel bowl.

The new factory springs seem to be 3 to 4 lbs heavier than the original but should not increase the pressure to what you are seeing.

 

How often do you change your fuel filter? I just rebuilt my FPR with parts from Bob since it was sticking and causing spikes up near 100 psi. At 360,000 miles my parts were nowhere near that dirty.

If it is a restriction in the return line, remove the fuel cap and blow some compressed air back down the return line into the tank to clear it out.

 

yea i was kinda surprized how dirty it was to ive changed filter more than any one elese i know probbibly every 15 20 k its whole life 264k now . i just droped the tank a few months ago and did the in tank mods and a baldwin fiter before the new bosch pump. the tank was pretty clean inside just the flote rod was rusting i was expecting worse. last night driving home seems like a ten pound differance was consistent at 62-67 now 72-78 consistent i think my gauge is fine it was 62 in the morning and when i pulled into shop after fpr higher. i post a pic later of the poppet it has two fresh grooves ln it .

greg my guide was differant it was grooved with that band seal orig. and the new was stepped with a oring i was able to install the new stuff didnt think so at first and relubed and pushed it in . that hole you were talking about earlier was straight thru just very small.

return line was wide open i did do the mod and when off i ran a little air and my buddy listened at the fill neck he said sounded like it was right in the neck. tank was almost empty.

 

look at the fresh gouges after i cleaned it . they were on two sides of the four . seems steady all the way to work 72-78 . no spikes

 

just updating after 4 or 5 tanks of fuel not one spike over 78 psi and is holding at 72-78 steady never goes below or above its a little higher than others have seen but i think its ok. i used the replacement spring that came in the ford rebuild kit .

 

couple weeks ago, on same tank of fuel, i noticed my pressure was up to 80psi, never spiked above it. Since then, about 3 tanks now, its back to settling around 69-72psi. I think i'll try that, clearing out the return line idea.

 

sounds right to me because when that thing sticks it pegs the gauge quick my gauge pegs at 100 so it might be more.