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I don't have much advice for you on the fuel pressure regulator. I know if you find fuel in the vac line you need a new FPR.
Did you replace the fuel pump with a used unit? it may be that the check valve in the replacement pump is faulty.
Or it may be that you caused a small break/perforation in one of the fuel lines by moving it when you were working with them...
There are others who have dealt with similar problems. Please do a search of the forums to find more info.
I made a post about possibly using an external check valve on this thread:
http://www.fcpgroton.com/product-exec/product_id/5151/nm/1985_1992_Volvo_740_Turbo_Fuel_Pump_Check_Valve/category_id/151
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