Volvo 240/740/760/780/940/960 1990-1998

Fuel Pressure Regulator

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REMOVAL & INSTALLATION



2.3L 4-Cylinder and 2.8L 6-Cylinder Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel lines from the pressure regulator.
  6.  
  7. Remove the vacuum line from the pressure regulator.
  8.  
  9. Remove the pressure regulator-to-bracket retaining bolts/nuts.
  10.  

To install:
  1. Install the pressure regulator in the bracket and tighten the retaining bolts/nuts.
  2.  
  3. Install the vacuum line.
  4.  
  5. Install and tighten the fuel lines.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start vehicle and check for leaks.
  10.  
  11. Ensure fuel pressure is correct.
  12.  
  13. Shut engine off and install the protective cover on the fuel rail.
  14.  

2.9L 6-Cylinder Engine; 2.3L and 2.4L 5-Cylinder Engines

See Figures 1, 2, 3, 4 and 5

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the fuel rail assembly.
  6.  
  7. Remove the vacuum line from the pressure regulator.
  8.  
  9. Remove the fuel lines from the pressure regulator.
  10.  
  11. Remove the pressure regulator from the fuel rail.
  12.  

To install:
  1. Lubricate the O-ring on the pressure regulator and the O-rings on the injectors with petroleum jelly or equivalent.
  2.  
  3. Install new pressure regulator ensuring O-ring seats properly.
  4.  
  5. Install and tighten the fuel lines to the regulator.
  6.  
  7. Install the vacuum line to the pressure regulator.
  8.  
  9. Install the fuel rail assembly. Ensure that the O-rings seat properly.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the vehicle and check for leaks.
  14.  
  15. Check that the fuel pressure is correct.
  16.  
  17. Shut the engine OFF and install the protective cover on the fuel rail.
  18.  



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Fig. Fig. 1: Remove the pressure regulator retaining bolts



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Fig. Fig. 2: Remove and safely store the spacers that go under the retaining bolts



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Fig. Fig. 3: Lift the regulator off of the fuel rail



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Fig. Fig. 4: Remove the O-ring from the pressure regulator port; install a new O-ring during assembly



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Fig. Fig. 5: Also replace the copper gasket on the pressure regulator body to prevent leaks

 
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