Removal and Replacement
Fuel pressure regulator, replacement
Fuel pressure regulator, replacement
Special tools:
999 5484 Adapter 999 5484 Adapter
999 5533 Holder 999 5533 Holder
999 5972 FIXTURE 999 5972 Fixture
Note! Click here if you are working on the S80.
Draining fuel system
- Drain the fuel system. See Fuel system pressure release Fuel System Pressure Release.
Preparation
5-door car:
- remove all floor covers and fold the carpet to one side
- remove the cover over the fuel pump fitting.
4-door car:
- fold forward right rear seat
- remove the luggage compartment mat
- fold aside the wheel housing panel's corner at the shock absorber mount
- remove the cover over the fuel pump fitting.
Disconnecting return line
- Carefully remove the quick-coupling for the return line from the fuel fitting.
- The return line is the one that is not yellow-marked.
Use tool 999 5666 Wrench 999 5666 Wrench. Move the coupling's outer sleeve upward. Avoid crushing the sleeve.
Removing connectors
- Unplug all connectors located in the bracket.
- Make sure that the wiring running down through the hole at the fuel fitting is in the clear and can accompany the tank down when it is lowered later on.
Removing filler pipe
- Remove the lock ring that presses out the rubber seal.
- Disconnect the rubber seal from the body.
Removing delivery line
- Loosen the delivery line from the fuel pipe at the engine.
- Disconnect the fuel pipe rail and loosen the delivery line.
- Remove the delivery line from the holder.
Removing pressure regulator
- Remove the hose that is connected to the pressure regulator's reference air connection.
- Loosen the return line from the bracket above the fuel filter.
- Loosen the delivery line from the fuel filter.
Removing fuel tank
- Place mobile jack with fixture 999 5972 FIXTURE 999 5972 Fixture under the tank, check that the lifting table is level so that the tank is not damaged.
- Loosen the tank straps and lower the tank slightly.
Removing front holder
- Loosen the front holder for the fuel lines.
- Lower the tank some more.
Installing pressure regulator
- Loosen the upper holder for the fuel lines.
- Remove the old pressure regulator.
- Connect the new pressure regulator's quick-coupling for the fuel fitting and pull it backwards along the delivery line.
- Install fuel lines and wiring on the upper holder.
Installing fuel tank
- Raise the tank so much that fuel lines and wiring can be installed on the front holder.
- Install fuel lines and wiring on the front holder.
- Lay the wiring that is to be inserted in the body through the hole by the fuel pump fitting in correct position so that it is not trapped when the tank is installed.
- Raise the tank and tighten it to the body.
Installing pressure regulator
- Connect the delivery line's quick-coupling to the fuel filter.
- Secure the return line to the bracket above the fuel filter.
- Install fuel lines in the holders.
- Connect the hose for reference air to the pressure regulator.
- Fit the fuel pipe rail longitudinally.
- Press the fuel line into place in the fuel pipe rail.
- Hold up the fuel pipe rail against the floor and tighten down. Use new clips and sleeves.
- Connect the delivery line to the fuel pipe at the engine and install it in the holder. Close the holder.
Installing filler pipe
- Install the rubber seal at the tank cap.
- Check that the inner rubber seal is in position and that the drain pipe ends up inside of the inner seal.
- Check position of the ring (1). Lubricate the sealing face on the rubber cover (2) with Vaseline. Install the cover and the ring (4).
- Plug in the connectors for the fuel pump, level sensor, ABS-sensors, and any tank pressure sensor.
- Install panels, covers, and mats.