1992 Volvo 940 GL, AW70LFACTORY OEM SERVICE PROCEDURE

Fuel Pressure Regulator

  1. Before disconnecting, cover fuel line connector with shop towel to absorb any fuel spray. Connect Fuel Pressure Gauge (5011 ) between fuel line and fuel rail. Seal free end of hose with Plug (5266 ). Start fuel pumps. On 240, remove panel under right side of instrument panel and remove system relay. See Fig 1 . On 740 and 940, lift out central electrical unit and remove system relay. See Fig 2 .
  2. On 240, 740 and 940, connect a jumper wire between relay terminals No. 30 and 87/2. See Fig 3 . On 960, remove fuses No. 30 and 31. See Fig 4 . Connect a jumper wire between right fuse terminals. See Fig 4 . On all models, fuel pumps should start. Fuel filler cover can be removed to determine whether main pump is operating.
  3. Fuel pressure should be 42 psi (3.0 kg/cm2 ). If pressure is too low, pinch return hose by hand and check whether pressure rises. Do not allow pressure to exceed 86 psi (6 kg/cm2 ). If pressure rises rapidly, replace pressure regulator.
Fig 1: Locating Fuel System Relay (240)
G92E26108Courtesy of VOLVO CARS OF NORTH AMERICA.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.