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AWD Fuel Pump - comments on the job + pics V70-XC70 1998

posted by  jadnhm on  Sun Jul 26 01:59 CST 2009
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last visit: Tue May 22 18:03 CST 2012
[RELATED]

I earlier described my diagnosis procedure that traced my no-start problem to the fuel pump:
http://www.brickboard.com/AWD/volvo/1360418/V70/help_start.html

I also described the problem I had sealing my new wires through the top of the sending unit:
http://www.brickboard.com/AWD/volvo/1361372/V70/awd_fuel_pump_sending_unit_sealing_around_wires.html

I never did get any pics of the rig-job I did to make a FWD pump fit in the AWD assembly but I'm just as happy because I'm not proud of it anyway. It works but I only did it because I was really stuck. It's hard only having one car in the family - I need to have the car working every weekday morning and evening...

Anyway I did get some pics of the access hole I cut in the floor. There was one pic I found of this online, but it didn't give any indication about where the hold was, just what it looked like.

So first to describe where the hole has to be cut. If you're sitting in the passenger's side rear seat, right behind the front pass seat, the hole goes directly behind you right heel. Probably the best way to locate it is the lower bracket for the lower seat because it's smack dab in the middle of the hole you need to cut.

There are three fuel system lines running right along the left side of the hole/pump assembly (left if you're looking at it - towards the passenger side as opposed to towards the center) that you need to be careful of, and I did end up chopping through one of mine. I think I have them figured out on my car this way:
closest to center : fuel to engine
center line : evap line
closest to pass side : fuel return

Anyway, you can patch them up if you cut them so it's not the end of the world if you do hit them but be careful because two of them will probably have fuel in them. Using a power tool can be dangerous in this situation. Using a torch would be downright stupid.

Because the lower bracket for the seat was pretty much right in the center of the piece I needed to remove, I decided to only cut three sides away. This way, I could just fold it away and work on the pump, and then fold it back and lock it in exactly the right spot when I was done. I didn't want to mess up the rear seat at all and this seemed like the easiest way to do it.

You can view the pictures on flickr here:
http://www.flickr.com/photos/joeldunham/sets/72157621837695960/
--
1998 V70 AWD Turbo 195k+








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    AWD Fuel Pump - comments on the job + pics Cutting hole in floor V70-XC70 1998

    posted by  rkmacman on  Tue Aug 25 08:29 CST 2009
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    last visit: Thu Dec 12 07:58 CST 2013
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      AWD Fuel Pump - comments on the job + pics Cutting hole in floor V70-XC70 1998

      posted by  rkmacman on  Tue Aug 25 08:43 CST 2009
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      last visit: Thu Dec 12 07:58 CST 2013
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      I have always used a stove pipe shear for cutting a hole from the middle of my work. First I drill four 3/8" holes in the shape of the hole I want to make. The shear has a center cutter that you insert into your starter hole. You cut to the next 3/8" hole then turn and cut to the next hole and so on. The shear takes out a 1/8" ribbon of metal that you discard. To patch the hole, cut 1" wide strips of 22 gauge sheet metal and rivet them around the outside of the hole then rivet the hole patch in place. Be sure to caulk all surfaces before final assembly.
      I hope this can assist anyone attempting this project. It is much safer than using a grinder or even a sawsall.
      Happy motoring All, RK








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    AWD Fuel Pump - comments on the job + pics V70-XC70 1998

    posted by  someone claiming to be brad on  Tue Aug 11 05:15 CST 2009 [RELATED]

    Your pictures are extremely helpful as I am ready to take on this project --THANKS> Did you ever get the fuel seep repaired? Also, what cutting tool do you recommend for the opening and is that a double row of self tapping screws that
    you used instead of pop rivets?








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      AWD Fuel Pump - comments on the job + pics V70-XC70 1998

      posted by  jadnhm on  Tue Aug 11 06:09 CST 2009
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      last visit: Tue May 22 18:03 CST 2012
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      I did get my seeping around the wires fixed. It took numerous applications of the permatex fuel tank epoxy product.

      I cut the hole with my angle grinder and a cutting wheel. This was probably a bit dangerous as I ended up cutting the metal fuel line and could have easily started a fire. A good sharp cold chisel would probably work fine.

      I used self-tapping screws to fasten everything back up. Rivets would have been fine too - probably better. I wanted to be able to get it back apart easily in the future...

      Also I should mention that I destroyed the 'quick connect' fuel fittings that hook up to the assembly, and so I ended up cutting them off and attaching rubber fuel line in it's place. It's a tight fit but it worked out okay.

      As it turns out I've got to pull it apart again someday anyway because the system is losing prime in between starts and I figure I've got an air leak somewhere. I am planning to relocate the fuel filter and use rubber line and clamps as much as possible due to the reliability/replaceability.

      There isn't enough clearance between the top of the assembly and the underside of the floor to /just/ use rubber line, as it will crimp trying to make the bend, so steel elbows or preformed line are needed.


      --
      1998 V70 AWD Turbo 195k+








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    AWD Fuel Pump - comments on the job + pics V70-XC70 1998

    posted by  KlausC on  Sun Jul 26 02:25 CST 2009
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    last visit: Fri Oct 24 10:15 CST 2014
    [RELATED]

    Now we all know why Volvo doesn't supply an access hole, the seat bracket is in the way. WOW! What a job.

    Thanks for sharing it with us.

    Klaus
    --
    The more I learn, the more I forget. So why learn?







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