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 MANUALSVOLVO1993960 4D WAGON, AW30-43REPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROLS - BASIC TESTINGFUEL SYSTEMFUEL PRESSUREFUEL PUMP PRESSURE
1993 Volvo 960 4D Wagon, AW30-43
Fuel Pump Pressure
1993 Volvo 960 4D Wagon, AW30-43SECTION Fuel Pump Pressure
- Before disconnecting, cover fuel line connector using shop towel to absorb fuel spray. Connect Fuel Pressure Gauge (5011 ) between fuel line and fuel rail. Seal free end of hose using Plug (5266 ) or use Fuel Drainage Unit (981 2270 , 2273 and 2282 ). Start fuel pumps.
- Remove fuel injection fuses No. 30 and 31. See Figure . Connect jumper wire between fuse terminals No. 30 and 31. On all models, fuel pump should start. Fuel filler cover can be removed to determine whether main pump is operating.
- Fuel pressure should be about 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, pump and lines are okay. Replace pressure regulator and recheck line pressure. If pressure rises slowly, fuel filter, fuel pump strainer or fuel lines are blocked. If pressure does not rise, fuel pump is probably faulty.
- If pressure is too high, remove jumper wire between relay or fuse terminals. Remove return hose from pressure regulator, and blow in pipe. Remove vacuum hose from pressure regulator, and blow in pipe. If both hoses are open, pressure regulator is defective. Replace regulator, and recheck pressure.
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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.