Volvo Cars 1999-05

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Fuel tank
     
    Fuel pump connector
     
    Large plastic fitting nut using special tool 999-7093
     
    Fuel pump

    Click image to see an enlarged view

    Fig. Removing the large fitting nut from the fuel pump assembly

    Removing the large fitting nut from the fuel pump assembly
     

  6.  

To install:

  1. Install or connect the following:

    Fuel pump with new O-ring
     
    Large plastic fitting nut using special tool 999-7093
     
    Fuel pump connector
     
    Fuel tank
     

  2.  

4-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Tilt the rear seat forward and remove or fold back the trunk compartment carpet.
  6.  
  7. Remove or disconnect the following:

    Protective cover
     
    Fuel pump harness connector. Label the connections for the fuel lines.
     
    Fuel lines by pressing in the catches and pulling out the lines
     
    Cap nut using special tool 999 5622
     
    Pump unit
     

  8.  


NOTE
Replace the fuel pump immediately or reinstall the cap nut temporarily because the threaded collar swells.

To install:

  1. Install or connect the following:

    Pump unit. Ensure that the arrow points towards the marking on the fuel tank
     
    Cap nut using special tool 999 5622 and tighten to 37 ft. lbs. (50 Nm)
     
    Fuel pump harness connector
     
    Fuel lines
     
    Protective cover
     

  2.  
  3. Start engine and check for leaks.
  4.  


    Click image to see an enlarged view

    Fig. Installing the cap nut for the fuel pump.

    Installing the cap nut for the fuel pump.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Tilt the rear seat forward and remove or fold back the trunk compartment carpet.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Replace the fuel pump immediately or reinstall the cap nut temporarily because the threaded collar swells.



    Protective cover
     
    Fuel pump harness connector. Label the connections for the fuel lines.
     
    Fuel lines by pressing in the catches and pulling out the lines
     
    Cap nut using special tool 999 5622
     
    Pump unit
     

  8.  

To install:

  1. Install or connect the following:

    Pump unit. Ensure that the arrow points towards the marking on the fuel tank
     
    Cap nut using special tool 999 5622 and tighten to 37 ft. lbs. (50 Nm)
     
    Fuel pump harness connector
     
    Fuel lines
     
    Protective cover
     

  2.  
  3. Start engine and check for leaks.

    Click image to see an enlarged view

    Fig. Installing the cap nut for the fuel pump.

    Installing the cap nut for the fuel pump.
  4.  

6-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump harness connections
     
    Fuel fill and vent hoses
     
    Fuel supply and return lines
     

  6.  
  7. Loosen the lockring 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.
  8.  
  9. Remove the transfer pump from the sending unit.
  10.  

To install:

  1. Install the transfer pump on the sending unit. Install the sending unit in the fuel tank and tighten the lockring.
  2.  
  3. Install or connect the following:

    Fuel supply and return lines
     
    Fuel fill and vent hoses
     
    Fuel pump harness connections
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump harness connections
     
    Fuel fill and vent hoses
     
    Fuel supply and return lines
     

  6.  
  7. Loosen the lockring 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.
  8.  
  9. Remove the transfer pump from the sending unit.
  10.  

To install:

  1. Install the transfer pump on the sending unit. Install the sending unit in the fuel tank and tighten the lockring.
  2.  
  3. Install or connect the following:

    Fuel supply and return lines
     
    Fuel fill and vent hoses
     
    Fuel pump harness connections
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel pump harness connections
     
    Fuel fill and vent hoses
     
    Fuel supply and return lines
     

  6.  
  7. Loosen the lockring 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.
  8.  
  9. Remove the transfer pump from the sending unit.
  10.  

To install:

  1. Install the transfer pump on the sending unit. Install the sending unit in the fuel tank and tighten the lockring.
  2.  
  3. Install or connect the following:

    Fuel supply and return lines
     
    Fuel fill and vent hoses
     
    Fuel pump harness connections
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks.
  6.  

5-Cylinder Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  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. Remove or disconnect the following:

    Negative battery cable
     
    Access panel
     
    Fuel pump harness connectors
     
    Fuel supply and return lines
     

  8.  
  9. Loosen the lockring at the top of the fuel tank and remove the fuel pump module.
  10.  

To install:

Click image to see an enlarged view

Fig. Use a new seal when installing the fuel pump retaining nut-5-cylinder engines

Use a new seal when installing the fuel pump retaining nut-5-cylinder engines

  1. Install or connect the following:

    Fuel pump module with a new seal. Tighten the retainer to 30 ft. lbs. (40 Nm).
     
    Fuel supply and return lines
     
    Access panel
     
    Trunk carpeting
     
    Rear seat
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Tilt the rear seat forward and remove, remove rear seat cushion or fold back the trunk compartment carpet over the right-hand wheel well panel.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The supply line is marked with yellow tape, corresponding to the color marking on the pump.



    Protective cover
     
    Fuel pump harness connector
     
    Fuel supply and return lines using tool 999 5666
     



    Fitting nut using wrench 999 5485
     
    Pump unit and rubber gasket
     

  8.  

To install:

  1. Install or connect the following:

    Fuel pump with new gasket
     
    Fitting nut using wrench 999 5485 and tighten to 29 ft. lbs. (40 Nm)
     
    Fuel supply and return lines
     
    Fuel pump harness connector
     
    Protective cover
     

  2.  
  3. Start engine and check for leaks.
  4.  

 
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