Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSVOLVO1993940 TURBO, 4D SEDAN, AW71REPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROLS - SYSTEM/COMPONENT TESTSFUEL SYSTEMFUEL DELIVERYFUEL PRESSURE REGULATOR
1993 Volvo 940 Turbo, 4D Sedan, AW71
Fuel Pressure Regulator
1993 Volvo 940 Turbo, 4D Sedan, AW71SECTION Fuel Pressure Regulator
- Connect Fuel Pressure Gauge (5011 ) between fuel line and fuel rail. Seal free end of hose with Plug (5266 ). Start fuel pumps. Lift out central electrical unit and remove system relay. See Fig 1 .
- Connect a jumper wire between relay terminals No. 30 and 87/2. See Fig 2 . Fuel pumps should start. Fuel filler cover can be removed to determine whether main pump is operating.
- Fuel pressure should be 42 psi (3 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.
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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.