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Volvo Master
545 Answers
- Posted on Jun 04, 2009
Re: I need to replace the fuel pump in my 940 Volvo.
Disconnect battery ground strap before beginning to work on the fuel/electrical system. Do not smoke or have anything in the area which can ignite or cause sparks
- Drain enough fuel from tank to prevent spilling, no more than 4 gallons (16 liters) of fuel should remain. Use suitable pumping equipment.
- Remove floor mat and panel from trunk.
- Disconnect wiring harness connector to sending unit. Remove wires from connector.
- Disconnect ground wire to sender. Push wires through grommet.
- Remove cover for access to tank sending unit.
- All models: Disconnect from the fuel tank sending unit:
- Breather hose C
- Return hose A
- Supply hose B
- Filler hose D
- Wiring harness from clip E
- Clean area and unscrew fuel tank sender/pump cap or equivalent. Remove tank sender/pump and seal.
- Remove pump from sender/pump assembly.
INSTALLATION
- Inspect the pump for damage, feed pump hose and wiring for wear. Replace as needed.
- Install new pump to sender/pump assembly.
- Install rubber seal in neck of tank. Lubricate inside of seal.
- Install fuel tank sender/pump unit. Align it with the moulded joint (arrows) on tank.
- Apply rustproofing compound to exposed metal portions of tank sender.
CAUTION :
With tape or rubber caps, protect fuel sender openings from overspray.
- Torque fuel tank sender/pump lock ring to: 22 ft-lb (30 Nm)
- Reassemble components in reverse order. Use tie straps to secure all hoses and wiring.
Volvo 940
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