2001 Volvo S40FACTORY OEM SERVICE PROCEDURE

Testing While Driving Vehicle

NOTE: Use foam padding or clean shop towels to protect vehicle interior and body.
  1. Remove fuel rail cover. Connect Fuel Gauge (999-5011), or equivalent, to Adapter Hose (951-2614), or equivalent. See Fig 1.
    CAUTION: Ensure that hose follows rubber intake plenum trim and exits engine bay at rear corner of hood. Fuel gauge "T" valve MUST be outside closed hood. Incorrect arrangement will cause vehicle damage.
  2. Remove cap from fuel line fitting and attach Adapter Hose loosely. Place foam pad or shop towel between T-valve and mirror. Attach T-valve to left mirror using strap-ties.
  3. Connect fuel drainage hose to T-valve to prevent fuel from spilling past T-valve directly onto vehicle.
  4. Tighten Adapter hose fitting onto fuel rail. Turn ignition on and wait for fuel gauge to indicate starting fuel pressure.
  5. Start engine. Ensure that no more fuel will spill past "T" valve and remove fuel drain hose.
  6. Drive vehicle and read fuel pressure. Pressure should be approximately 32-45 psi (220-310 kPa). Pressure should be stable at constant load and should fluctuate during acceleration or engine braking. If not as specified, locate and repair fuel pressure leak. If pressure is OK, go to next step.
  7. Turn ignition off. Attach drain hose to "T" valve. Remove strap-ties from fuel gauge and open vehicle hood. Place Gauge inside engine compartment to prevent spilling fuel on vehicle body during removal.
  8. Place a container below fuel rail. Remove adapter hose fitting from fuel rail and wait for hose to finish draining before moving. When pressure checking equipment is removed, install cap onto fuel rail fitting. Install fuel rail cover.
Fig 1: Connecting Special Tools For Checking Fuel Pressure While Driving
G00236695Courtesy 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.

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