Trying to replace the fuel pump in a 2004 Volvo XC90 (2.5 non-turbo, 2WD).

I not an expert mechanic by any means but pretty decent at following directions and whatnot, but can't figure out for the life of me why it doesn't work.

After replacing fuel pump, engine won't catch. It sounds like it's not getting enough fuel, but I hooked a pressure gauge up and verified that there is at least some fuel coming into the fuel rail (just not sure if it's enough).

I'm wondering if there is some trick or adjustment or setting on a new fuel pump that some of you experienced folks might know about that I'm just not aware of.

Here are some pics of what the pressure gauge is showing:




Here is the gauge, hooked up to the fuel rail at the schrader valve (I removed the interior of the valve).




Here is what the gauge shows when attempting to start the car.





Here is what happens when attempting to start the car if you pump the accelerator quickly as it's attempting to catch.

I'm at wits end. I even tried putting the old fuel pump back in to test if it was just a bad pump (the old one wasn't completely busted, just not working right), and it's the exact same problem as the new one.

Also, I audibly verified that while the key is turned on, in the last position before cranking, both the fuel pump and the fuel sending unit are making noise for a couple seconds like they're priming.

Anyway...I know that's a lot but if anyone has any ideas before we shell out cash for a mechanic, I'd appreciate it!

 

I'm no expert on Volvos or your situation... but I wonder where is the fuel filter in this equation? Could it be so clogged... that your pump can't create enough pressure @ the rail(s)?

 

Fuel filter is on the passenger side near the rear wheel. You can see it without jacking up the car. If it is dirty or even covered in the black underside coat, it's time to change it. $25 part sold many places and takes about 5 minutes to change. Just be careful with the bolt holding on the filter bracket. Mine was rusted and broke in the threads, so now i've got a new fuel filter bracket held on by zip ties :-)