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Re: in-tank pre-pump replacement[240-260/80] posted by George Swift on
Thursday, 25 June 1998, at 12:19 a.m.
CAKE.
First, disconnect the return line underneath the car by the fuel tank. (14mm & 15mm wrenches)
Next, open the trunk and remove all the earthquake gear. Fold the carpet back from the hump over the differential/rear axle. Grab the black plastic cover near the spare tire and pull out the two plastic clips. disconnect the wiring connector and remove the ground for the pre pump. (phillips screwdriver) Then remove the cover for fuel level sender access. (two phillips screws)
Next, using a phillips, remove the discharge hose. (big hose). If the clamp is frozen, use a pair of dikes to cut the clamp off. Next pry off the fuel vent line. (small line) Using a lever, carefully rotate the lock ring counter- clockwise. After the lock ring is loose, lift the sender unit up about 1/2 '', then start turning the assembly counter-clockwise, while lifting up.
The first concern is to get the plastic (rubber sleeved) return line out first. Once the return line has splashed 2 drops of fuel in your eyes, carefully manipulate the sender out of the tank, watching for clearance between the opening and the wiring and float ball. The sender is in your hands.
Why did you take it out? Is it because the ''made in USA'' part failed? I knew that. Don't over tighten the little nuts that connect the wires, and use a new filter sock. Take your time. If you hurry this one, it takes longer.
--George Swift / Volvo Car Care / 760 868 1903