Replacing fuel pressure regulator

Special tools: 

9995533

9995972

Draining fuel system 

Fig 1: Identifying Fuel System Being Drained

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Drain fuel system

Preparations 

Fig 2: Identifying Cargo Compartment Carpet And Cover Over Fuel Pump (FP) Unit

Courtesy of VOLVO CARS OF NORTH AMERICA.

5-door cars: 

• remove all floor hatches and fold back carpet.
• remove cover over fuel pump (FP) unit.

4-door cars: 

• fold forward right rear seat
• remove cargo compartment carpet.
• fold back corner of wheel housing panel at shock absorber mounting.
• Remove cover over fuel pump (FP) unit.

Removing return line 

Fig 3: Identifying Quick-Release Connector On Return Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Carefully disconnect quick-release connector on return line from fuel pump (FP) unit.
• The return line is not marked in yellow.

Use tool 9995533 . Slide outer sleeve of connector upward. Avoid squeezing sleeve.

Disconnecting connectors 

Fig 4: Identifying Fuel Filler Pipe Ground Lead From Nut On Fuel Tank Level Sensor Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 5: Identifying Connectors On Bracket

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Disconnect all connectors on the bracket.
• Ensure that all cables routed through the fuel pump (FP) unit hole are free to follow the fuel tank when it is lowered.

Removing fuel filler pipe 

Fig 6: Identifying Rubber Seal

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Remove circlip securing rubber seal.
• Release rubber seal from bodywork.

Removing fuel line rail 

Fig 7: Identifying Fuel Line Rail

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Remove the fuel line rail
• Disconnect fuel lines from holders.

Removing pressure regulator 

Fig 8: Identifying Fuel Pressure Regulator

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Remove the hose connected to the pressure regulator reference air connector.
• Disconnect delivery pipe from fuel line by engine.
• Disconnect delivery pipe from fuel filter.
• Remove return line from bracket above the fuel filter.

Removing fuel tank 

Fig 9: Identifying Mobile Jack With Fixture

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Position mobile jack with fixture 9995972 under fuel tank, check that the lifting platform is flat so as not to damage the fuel tank.
• Undo tank retaining straps and lower tank slightly.

Removing front bracket 

Fig 10: Identifying Front Fuel Line Bracket

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Undo the front fuel line bracket.
• Lower fuel tank further.

Installing new pressure regulator 

Fig 11: Identifying Pressure Regulator

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Undo the upper fuel line bracket.
• Remove the old pressure regulator.
• Connect the new pressure regulator quick-release connector to the fuel pump (FP) unit and route it forward along the delivery line.
• Install fuel lines and cables in the upper bracket.

Installing fuel tank 

Fig 12: Identifying Fuel Lines And Cables

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Raise the tank so that fuel lines and electrical cables can be installed in the front mounting.
• Install fuel lines and cables in the front bracket.
• Arrange cables running through the fuel pump (FP) unit hole so that they are not trapped when the tank is installed.
• Raise the fuel tank and fix it to the bodywork.

Installing pressure regulator 

Fig 13: Identifying Fuel Pressure Regulator

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Install the return line in the bracket above the fuel filter.
• Connect delivery pipe quick-release connector to fuel filter.
• Install fuel lines in holders.
• Connect delivery pipe to fuel line by engine.
• Connect reference air hose to pressure regulator.
• Locate cable fuel line rail lengthwise.
• Press fuel lines into place in fuel line rail.
• Hold fuel line rail against the floor of the car and tighten.

Installing fuel filler pipe 

Fig 14: Identifying Circlips, Rubber Cover Sealing Surface And Drain Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Install filler housing around top of filler pipe.
• Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
• Check that circlip (1) is in position. Lubricate rubber cover sealing surfaces (2) with petroleum jelly. Install cover and circlip (4).
• Connect connectors to fuel pump (FP), level sensor, ABS sensors and fuel tank pressure sensor.
• Install panels and carpets.