Volvo 240/740/760/780/940/960 1990-1998

Fuel Pump

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REMOVAL & INSTALLATION



2.3L 4-Cylinder and 2.8L 6-Cylinder Engines

See Figures 1 and 2

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Remove the fuel tank.
  8.  
  9. Loosen the lock ring at the top of the fuel tank and remove the sending unit with the transfer pump attached. Note the direction of the float in the tank.
  10.  
  11. Remove the transfer pump from the sending unit.
  12.  

To install:
  1. Install the transfer pump on the sending unit.
  2.  
  3. Install the sending unit in the fuel tank and tighten the lock ring to specification. Do not overtighten the lock ring as the plastic threads on some fuel tanks are easily stripped.
  4.  
  5. Install the fuel tank in the vehicle.
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for leaks.
  12.  



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Fig. Fig. 1: Fuel pump assembly for the 2.3L 4-cylinder engine



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Fig. Fig. 2: Fuel pump assembly for the 2.8L 6-cylinder engine

2.3L and 2.4L 5-Cylinder, and 2.9L 6-Cylinder Engines

See Figures 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 and 16

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Tilt the rear seat forward and remove or fold back the trunk compartment carpet over the right-hand wheel well panel.
  6.  
  7. Disconnect the fuel pump electrical connections.
  8.  

Take note of the color markings on the hoses; colored tape should identify hose locations on the pump.

  1. Detach the quick-connect couplers for the fuel delivery and return hoses.
  2.  
  3. Remove the pump unit by unscrewing the retaining nut using tool 999-5485 or equivalent.
  4.  
  5. Lift the pump out carefully and remove the rubber seal. When lifting the pump out, do not grab the connections with pliers or any other sharp tools that might cause damage and result in fuel leakage.
  6.  

To install:

WARNING
Install the retaining nut while the pump is removed, otherwise the tank connection may swell and the nut will be difficult to install.

  1. Install a new dry seal, making sure that it is seated properly. Lubricate the top and outer side of the seal with petroleum jelly.
  2.  
  3. Install the pump with the heater connection facing towards the right side of the vehicle.
  4.  
  5. Install the fuel pump retaining nut and tighten it to 30 ft. lbs. (40 Nm) using tool 999-5484 or equivalent.
  6.  
  7. Apply a small amount of petroleum jelly to the delivery and return hose ends and install them on the pump. The delivery line is marked with yellow tape, which should be matched to the yellow marked pump outlet. Make sure that the quick-connectors are properly seated on the pump.
  8.  
  9. Connect the electrical connections, making sure that they are in the correct position. Install the panels and carpets.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Run the engine and check for leaks.
  14.  



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Fig. Fig. 3: Remove the clips retaining the carpet ...



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Fig. Fig. 4: ... to expose the fuel pump access cover



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Fig. Fig. 5: The rear seats can be folded down from the inside, but this lever must be in the up position



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Fig. Fig. 6: Release this lever from inside the car to lower the rear seats



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Fig. Fig. 7: Remove the trim retaining bolt from the bottom of the panel



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Fig. Fig. 8: Remove the seat back striker using a T30 Torx® bit



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Fig. Fig. 9: Carefully push the trim back ...



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Fig. Fig. 10: ... to access the fuel pump harness connections



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Fig. Fig. 11: Remove the fuel pump access cover retaining bolts



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Fig. Fig. 12: When the cover is removed, the fuel pump is visible



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Fig. Fig. 13: Detach the quick-connect fittings ...



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Fig. Fig. 14: ... and remove the fuel lines from the pump



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Fig. Fig. 15: Use wrench 5485 or equivalent to remove the fuel pump retaining ring



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Fig. Fig. 16: After the retaining ring is removed, lift the pump out of the tank

PRESSURE TESTING



See Figures 17 and 18

  1. Relieve the fuel pressure.
  2.  
  3. Connect a fuel pressure gauge 5011 or equivalent, between the fuel line and distribution manifold or Schrader valve if equipped.
  4.  

Position a shop towel in place to catch any spilled fuel when the fuel line connections are removed.

  1. On 700 and 900 Series vehicles, remove the seat belt reminder, since this makes the test more easily performed. It is located in the middle of the top row in the fuse box.
  2.  
  3. Start the fuel pump (fuel pump relay removed) by connecting a jumper lead between terminals 30 and 87/2 on the relay socket. Verify the pump operation by removing the fuel cap and listening.
  4.  
  5. Note the gauge reading. The fuel pressure should be approximately 43.5 psi (300 kPa).
  6.  
  7. Remove the jumper lead.
  8.  
  9. Relieve the fuel system pressure and remove the pressure gauge.
  10.  
  11. Re-install the fuel pump relay.
  12.  



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Fig. Fig. 17: The Schrader valve is located on the fuel rail-remove the protective cap to test fuel pressure



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Fig. Fig. 18: Install the gauge and adapters between the fuel feed line and fuel rail on models without a Schrader valve

 
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