Other S60 Problem: new pump high fuel pressure

[wrgallant]

chassis number is 121587

I've tried 3 different pumps - volvo, bosch & delphi and had the same pressure at the rail for all of them.

[Clan]

Originally Posted by wrgallant

chassis number is 121587

I've tried 3 different pumps - volvo, bosch & delphi and had the same pressure at the rail for all of them.

a tricky one ... you would assume a pump would give that kind of pressure if the outlet was blocked ... hard to say much more without being there... have any pipes been put back on the wrong nipples ?

[wrgallant]

There are 2 hoses to the pump - the pressure side that goes to the filter and a 2nd hose that should be a return but it doesn't connect to anything. Line just dumps above the tank

[Clan]

Originally Posted by wrgallant

There are 2 hoses to the pump - the pressure side that goes to the filter and a 2nd hose that should be a return but it doesn't connect to anything. Line just dumps above the tank

that's correct yes !

[wrgallant]

Any idea why the return line is not connected to anything?

[Clan]

Originally Posted by wrgallant

Any idea why the return line is not connected to anything?

I dont understand, there is no return is there ? the pressure relief valve returns within the fuel pump casing .. where does that return line you mention come from on the car?

[wrgallant]

The return line just dead ends on top of the tank.
Should it be connected into the pressure line somewhere?

Can't find a diagram anywhere that shows where the return line goes.

Might be time to drop the tank

[Clan]

Originally Posted by wrgallant

The return line just dead ends on top of the tank.
Should it be connected into the pressure line somewhere?

Can't find a diagram anywhere that shows where the return line goes.

Might be time to drop the tank

well there isn't one on your car , traditionally the return line goes from the fuel pressure regulator on the fuel rail and returns the excess fuel back to the tank . you need to trace where that pipe you talk of comes from ..

[wrgallant]

I dropped the tank and found the return line connected to nothing.
Looks like it broke off at the fitting but I can't find anywhere that it looks like it would have attached at the front of the tank.

[Clan]

Originally Posted by wrgallant

I dropped the tank and found the return line connected to nothing.
Looks like it broke off at the fitting but I can't find anywhere that it looks like it would have attached at the front of the tank.

but there isnt a return line on your system is there ... where does the other end go ?