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General » How-To » Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement (5) 1 Vote(s)
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1warhelion  is currently offline 1warhelion
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Posts: 91
Location: Norwalk, CT
Registered:
May 2005
 
Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sat, 16 February 2008 21:27 Go to next message
Hi all!

As promised, but a little delayed - Here we are the replacement of the Fuel Pressure Regulator or 'FPR'.

Reason for replacement: For about a two years, I have had continued problems starting my rather non modified S40 engine. It progressively got worse in being able to start. It was especially hard to start in the colder weather. It could take 3-5 turns of the ignition key to prime the engine to crank it over. Thanks to the help of fellows on this board I was able to deterimine the cause. Leaking fuel pressure from the FPR.

*(As a side note; the next step was to replace the injector o-rings which can be bought for a set $10, and can be done the same time as replacing the FPR)

Cost of OEM part as of 2008: $108 (including tax) available for ~$80 online.

OEM Part Number: 8658092 (for 2001 Volvo S40)

For a novice weekend grease monkey this engine operation will take from 30-45 minutes (with clean-up...more explaination to come). The more experience professional should be able to do this in 15-20 minutes.

The following is the basic description of tools and steps to complete this repair... (Enjoy) Very Happy
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1warhelion  is currently offline 1warhelion
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Posts: 91
Location: Norwalk, CT
Registered:
May 2005
 
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sat, 16 February 2008 21:36 Go to previous messageGo to next message
Step 1: Gather your tools... and ice your beer Very Happy

Tool inventory needed:

- Loclite thread lock
- small regular screwdriver
- philps head scredriver
- 2 torque bits - size 20 & 30 (can buy whole set on ebay for $8)
- 10mm rachet socket and racket (extensions helpful)
- pliers
- Vaseline (to lube the o-ring on the new FPR)
- Rags!! to soak up gas that will spill all over the freaking place when you remove the old FRP. (more on that later)
- Bottle openner (post game celebration)http://s40concepts.net/forum/index.php?t=getfile&id=15036

Attachment: Step 1 FPR Volvo S40.jpg
(Size: 34.18KB, Downloaded 2926 time(s))

[Updated on: Sat, 16 February 2008 21:58]

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1warhelion  is currently offline 1warhelion
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Posts: 91
Location: Norwalk, CT
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May 2005
 
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sat, 16 February 2008 21:52 Go to previous messageGo to next message
Step 2:

Getting your hand dirty...

In step 2, I have admit, I am not the greatest mechanic, but I am surprised at the lack of information available to locate and id the FPR on the engine. So, to remedy this I am including a few pictures to show the way...

Part 1 picture shows what you will see when you open the hood...
http://s40concepts.net/forum/index.php?t=getfile&id=15037

Part 2 picture show what you will see after removing the plastic engine cover. To my surprise, there is only one torque bolt holding the FPR onto the fuel rail. You will want to release any pressure from the fuel rail with the pressure valve located at the top of the fuel rail on the left hand side. See pictures on my post for replacing the fuel pump for exact location.
http://s40concepts.net/forum/index.php?t=getfile&id=15038

Part 3 - Remove the vaccum hose to make room to remove the one torque screw (size 20)- !! Be sure to place a rag over the hole exposed after this step. The reason being, I learned the hard way that about a 1/4 cup of gas ran out of my fuel rail onto my engine after removing the old FPR - who know the fuel rail would be full of fuel?? Shocked
http://s40concepts.net/forum/index.php?t=getfile&id=15039

Attachment: Step 2 Part 1.jpg
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Attachment: Step 2 Part 2.jpg
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Attachment: Step 2 Part 3.jpg
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[Updated on: Sun, 17 February 2008 07:28]

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1warhelion  is currently offline 1warhelion
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Posts: 91
Location: Norwalk, CT
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Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sat, 16 February 2008 21:57 Go to previous messageGo to next message
Step 3:

Removal of the FPR is very easy;

-Remove the one torque bolt- but do not remove from fuel rail yet!!!!!!!!!!!

- disconnect the small vaccuum hose below the FPR with a pair of pliers.

- disconnect the top of the FPR
http://s40concepts.net/forum/index.php?t=getfile&id=15040

be sure to have a rag handy to cover the quick release, fuel will come out, only a little.

Attachment: Step 3 - FPR Quick release.jpg
(Size: 25.25KB, Downloaded 2867 time(s))

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1warhelion  is currently offline 1warhelion
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Posts: 91
Location: Norwalk, CT
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May 2005
 
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sat, 16 February 2008 22:12 Go to previous messageGo to next message
Step 4:

When getting ready to replace the old FPR, have the new FPR ready for immediate replace.

- Lube up the o-ring of the FPR with Vaseline

- With the new FPR in one hand - pull out the old FPR and immediate plug the fuel rail and the gas running out with the new FPR. Work the new FPR into the fuel rail (it will be a tight fit).

- After the new FPR is in place, connect the top fuel input and then the lower vacuum tube.

- Next secure the FPR with the torque screw

!!!(Be sure to add some Loctite to the tread for some assurance it will not vibrate out when the engine is running - you'll be in big trouble then)

and clean up any fuel the spilled on the engine. I used a air compressor to blow out all the fuel I spilled then let the whole engine air out over night (a little anal, but I have had one to many cars catch on fire.http://s40concepts.net/forum/index.php?t=getfile&id=15041


- After clean-up you are good to go. I recommend turning your key to the point before cranking 5 times to prime the engine. This will get fuel back into the lines you lost replacing the FPR - no need to bleed the system or worry about air bubbles.

And BANG! Your engine will turn over like the first day you drove her off the dealer lot.

I hope this information will be useful for those that run into this problem.

Attachment: Step 4- Post replacement.jpg
(Size: 34.23KB, Downloaded 2860 time(s))

[Updated on: Sun, 17 February 2008 07:27]

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GerBeGurGya
Senior Member


Posts: 4083
Location: The Bronx
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May 2005
icon14.gif  Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sun, 17 February 2008 07:19 Go to previous messageGo to next message
Very nice write up perhaps the best made ever.You really spent some time and effort on this one.Thank you.
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1warhelion  is currently offline 1warhelion
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Posts: 91
Location: Norwalk, CT
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Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sun, 17 February 2008 07:31 Go to previous messageGo to next message
Thanks man, I was so freaking happy when this solved my engine issue, I thought I would add some of my mad corporate powerpoint skills to this write-up Laughing Laughing
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mdocster
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Location: Tampa Bay Area, Florida
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February 2004
   
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sun, 17 February 2008 14:08 Go to previous messageGo to next message
GREAT write-up! Its very easy to follow and I'm sure it will help a lot of us Smile
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just4fozi@yahoo.com  is currently offline just4fozi@yahoo.com
NerfHerder


Posts: 184
Location: South Africa
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February 2008
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Tue, 25 March 2008 23:45 Go to previous messageGo to next message
Hmmm...

Sometimes my car doesnt start immediately. Very seldom though, and mostly on cold days.

It takes about 2 attempts before it goes.

Will this fpr issue also affect performance?
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BrianT  is currently offline BrianT
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Location: St.Louis, MO
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February 2003
 
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Wed, 02 April 2008 13:30 Go to previous messageGo to next message
thank you for this write up. I just replaced my FPR in 20min...and yes, a lot of fuel comes out

[Updated on: Wed, 02 April 2008 13:30]

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BrianT  is currently offline BrianT
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Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Thu, 03 April 2008 18:01 Go to previous messageGo to next message
so does the o-ring on the plastic housing for the FPR actually go in the fuel rail, or does it form a seal between the fuel rail and FPR housing?
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just4fozi@yahoo.com  is currently offline just4fozi@yahoo.com
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Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Fri, 04 April 2008 01:59 Go to previous messageGo to next message
I removed my engine cover last night and my fpr does not sit in the same place as the above pics Confused

I have a Phase1 S40 T4
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bpray9223  is currently offline bpray9223
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Posts: 306
Location: Westfield, MA
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March 2008
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sun, 06 April 2008 16:15 Go to previous messageGo to next message
Is this the place where I would hook up a vacuum line to go to my aftermarket BOV?
http://s40concepts.net/forum/index.php?t=getfile&id=15444

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1clean01  is currently offline 1clean01
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February 2005
 
Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sun, 06 April 2008 16:30 Go to previous messageGo to next message
bpray9223 wrote on Sun, 06 April 2008 19:15

Is this the place where I would hook up a vacuum line to go to my aftermarket BOV?
http://s40concepts.net/forum/index.php?t=getfile&id=15444


NO! That is for the fuel pressure regulator. The line you want is the furthest back from the front of the throttle body.
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bpray9223  is currently offline bpray9223
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Re: Engine will not turn over - (FPR) Fuel Pressure Regulator Replacement Sun, 06 April 2008 17:12 Go to previous messageGo to previous message
Do you have a picture of where it is?
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