RK PEV IMPCO Repair Kits For Two Stage Regulator
Brand Name:IMPCO
Model Number:RK-COBRA
Minimum Order Quantity:24
Delivery Time:8 weeks
Payment Terms:T/T
Place of Origin:USA
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Hefei Anhui China
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RM1608,Xingke Building,58Feixi Road, Hefei Anhui 230022 P.R.C
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IMPCO RK-PEV , Two-Stage Regulator EV / PEV Repair Kit , Color
Coded Diaphargms
MODEL EV & PEV SERIES
TWO-STAGE REGULATOR REPAIR KIT INSTRUCTIONS
Important: Any maintenance, service or repair should be performed
by trained and experienced service technicians. Proper tools and
equipment should be used to prevent injury to the servicing
technician, property or system components. Service repairs should
always be performed in a safe environment and the technician should
always wear protective clothing to prevent injury.
The IMPCO PPI-47 repair kit instructions will provide the
technician information to successfully repair the model EV and PEV
regulators. Always inspect the major casting pieces for damage,
corrosion or cracks before attempting a service repair. Be sure the
repair kit part number you are using is correct for the regulator
being serviced. Diaphragms are color coded and have different
performance characteristics:
BLACK: Hydrin diaphragm material is the standard material and is
well suited for the most common applications.
YELLOW: Silicone diaphragm material is the optional upgrade
material that provides excellent flexibility in cold weather
climates and is more resistant to chemical contamination.
BLUE: Fluorosilicone diaphragm material provides excellent high and
low temperature durability with increased chemical resistance. This
material is recommended for turbo applications.
REBUILD INSTRUCTIONS
1. Under normal conditions, installation of a complete repair kit
should be necessary only at the time of a major engine overhaul or
when the converter has been out of service for an extended period
of time. Each kit includes the necessary gaskets, diaphragms, seals
and some replacement screws.
2. PEV Only (Skip for EV): Remove the spring retainer housing cover
screws (23) and cover (24). Remove the housing gasket (25) and
secondary spring (7).
3. Remove the cover screws (2) and the cover (3) from the
regulator.
4. Remove the secondary diaphragm assembly (4).
5. Remove screws (10) from the primary diaphragm cover (11).
6. Early Model Only (Skip for Later Models): Remove secondary lever
fulcrum pin (8) and secondary lever (5).
7. Later Model Only (Skip for Early Model): Remove the screw (21)
and washer (22) holding the fulcrum pin (8).
8. Remove primary cover (11) and primary springs (12).
9. Remove primary diaphragm (13).
10. Remove primary pin (14).
11. Remove remaining screws from main body (10).
12. Separate upper main body (15) from lower body (18).
13. Remove body gasket (16).
14. Remove primary seat (17).
15. Install new primary seat (17) to lower body (18) with rubber
face down towards the primary orifice.
16. Install new gasket (16) to main body. Be sure to align the
gasket as shown using the dowels and primary pin channel to retain
the gasket.
17. While holding the outer edges of the main body gasket (16),
place the upper body (15) on top of the lower body (18) with seat
installed. Align the screw holes and be sure the gasket is flat
around the circumference of the body.
18. Install the screws (10), and tighten them until they are snug,
to retain the two pieces for now.
19. Install new primary pin (14).
20. Install new primary diaphragm (13) using dowel locators to
align and retain as shown.
21. Install primary springs (12) using spring locators to align and
retain as shown.
22. Press primary cover (11) in place over the primary springs (12)
and diaphragm assembly (13). Insert the two inner screws (9) in the
location shown and torque to 22-28 in-lbs. (2.5-3.2 Nm).
23. Early Models: Replace and tighten screws (10) except for the
one shown in left photo. Starting at one side of the regulator
body, use a diagonal pattern to torque each screw (10) to 35-45
in-lbs. (4.0-5.1 Nm).
Later Models: Replace and tighten screws (10). Starting at one side
of the regulator body (15), use a diagonal pattern and torque all
screws (10) to 35-45 in-lbs. (4.0-5.1 Nm).
24. Slide the pin through the larger of the two hole openings of
the lever (5) and place over a socket that will support the area of
the lever around the hole. Using a hammer, knock in the pin (26)
through the smaller hole until it is even on both sides.
25. Inspect the tabs on the lever (5) to verify they are not bent
and the pin (26) is centered.
26. Insert the seat (6) by pressing the nub through the hole in the
lever (5).
27. Early Models Only (Skip for Later Models): Replace the
secondary lever and seat assembly (5 & 6) and fulcrum pin (8).
28. Later Models Only (Skip for Early Models): Insert the screw
(21) and washer (22) securing the fulcrum pin (8). Secure the screw
until snug.
29. Check secondary lever height. While holding the secondary seat
(5) lightly against the secondary orifice. Measure the distance
using a straight edge between the top of the lever pin and body
casting edge. The lever height must be set to 1/32 of an inch
(2.4mm) below the top of the casting. If the lever height is
incorrect, continue to Step 30. Once the lever height is correct,
skip to Step 31.
30. If necessary, remove the fulcrum pin (8) and lever (5) and bend
slightly if required. Do not attempt to bend the lever when
installed--unnecessary force on the lever may damage the secondary
seat (6).
31. Early Models: Once the lever height is correctly set, replace
the remaining screw (10) and torque to 35-45 in-lbs. (4.0-5.1 Nm).
Later Models: Remove screw (21) and washer (22). Apply Loctite 242
to screw threads and torque to 17-23 in-lbs. (1.9-2.6 Nm). Refer to
photo in Step 28.
32. EV Only (Skip for PEV): Slip the spring (7) under the secondary
lever (5) making sure it is retained by the two tabs at the sides
and the single tab punched through the top of the lever.
33. Replace the secondary diaphragm (4) engaging the slotted link
to lever pin shown.
34. Install the cover (3) to the body aligning the screw holes.
Install screws (2) finger tight, then torque to 25-35 in-lbs.
(2.8-4.0 Nm), using a diagonal pattern.
35. PEV Only (Skip for EV): Place the secondary spring (7) on the
secondary diaphragm (4) perch. Install the gasket (25).
36. PEV Only (Skip for EV): Align the spring retainer housing screw
holes to the cover (3) and insert cover screws (23). Torque to 7-11
in-lbs. (0.8-1.2 Nm).
37. EV Only: Apply 100 psi (6.9 Bar) of air pressure to the inlet
side of the regulator and test for leaks. Draw a soap bubble across
the regulator outlet to verify that no air is flowing through the
outlet. If air escapes, the rebuild has failed and the regulator
must be replaced. Actuate the primer button and the soap bubble
should burst and air flow should be noted at the regulator outlet.
Use soap and/or a commercial leak detector solution to inspect the
gasket seals around the perimeter of the converter for leaks. If no
leaks are found, the repair is now complete.
RK PEV IMPCO Repair Kits For Two Stage Regulator
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