Pressure regulator, replacement

Draining fuel system 

Fig 1: Identifying Fuel System Drainage Equipment

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Drain fuel system according to Drainage of fuel system .

Removing hoses and covers 

Fig 2: Identifying Hoses And Covers

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

• fuel rail cover
• Vacuum hose from fuel pressure regulator.
• Fuel line from fuel pressure regulator.
• When removing fuel rail see Removing fuel rail .

Removing pressure regulator 

Fig 3: Identifying Pressure Regulator

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

• Both screws on the pressure regulator and paper under the pressure regulator to catch any spillage.
• Regulator

Installing 

Install:

• new pressure regulator. Lubricate pressure regulator O ring with petroleum jelly.
• Install and tighten pressure regulator screws
• Fuel line to pressure regulator.
• Vacuum hose to pressure regulator.
• Cover over fuel rail.

Special tools: 

9995533

Draining fuel system 

Fig 1: Adapter Connected To Fuel Draining Unit

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Drain fuel system according to Drainage of fuel system .

Removing 

Fig 2: Identifying Fuel Rail Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

• B5234T/B5204T/B5234T5: Upper charge air pipe.
• Fuel rail cover.
• Injector connectors.
• Fuel line clamps.

Install holder 9995533 according to Injector valve, replacement .

Fig 3: Identifying Fuel Rail Assembly And Screws

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

• Vacuum hose from pressure regulator.
• Screws holding fuel rail. Lift fuel rail with injectors attached.

Fig 4: Identifying Fuel Pressure Regulator

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

• Both pressure regulator screws and place paper under the pressure regulator to soak up any fuel spillage.
• Pressure regulator.

Install:

• New pressure regulator.
• Pressure regulator screws and tighten.
• All rubber damping elements on intake manifold.

Lubricate injector O-rings with petroleum jelly.

New connector for model year 1995 

Fig 5: Turning Fuel Rail Delivery Line

Courtesy of VOLVO CARS OF NORTH AMERICA.

The delivery line connector is inserted into the fuel rail and sealed with an O ring. The delivery line is locked into place on the fuel rail by turning the fuel rail approximately 90°  in relation to the delivery line. This causes a metal tongue on the connector to lock in a groove on the fuel rail.

Installing 

Fig 6: Identifying Fuel Rail Components

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

• All rubber damping elements on intake manifold.
• Fuel rail on the intake manifold.
• New screws and tighten to 10 Nm.
• Fuel line clamps.
• Remove injector holders.
• Injector connectors. Check that each connector has a rubber seal.
• Covers over fuel rail and throttle pulley.
• B5234T/B5204T/B5234T5: upper charge air pipe.