Dear jd620,

Hope you're well and stay so! I'm pretty sure that the Bosch main fuel pump's plastic connectors are unique to that pump format. They came with the pump: Volvo did not - so far as I can tell from Volvo VADIS, a superseded dealer parts/service database - supply these connectors.

Around each of the pump's metal stud contacts, is a plastic sheath, onto which latches the wiring harness connector's contacts. When that plastic sheath is pressed onto the metal stud contact, the sheath locks into a circumferential recess in the metal stud. Thus, even if you found a used pump in a salvage yard, the plastic sheaths - embrittled by time - likely would break when you tried to pry them free.

The only way to replace the sheaths is to get them new, and press them into place. You'd have to contact Bosch and find out if they still have these sheaths. That's a long shot, to say the least.

As you've soldered the wires to the pump's metal studs, you can weather-proof the connections by using butyl rubber tape, of the sort used to install windshields. Butyl rubber is very sticky. Clean the connections with a solvent (e.g. alcohol, methyl ethyl ketone [butanone], or acetone) to remove any dirt, grease etc. Starting at the base of each pump stud, wrap the tape over the connectors and for a further inch along the wires. Compress the tape with your fingers. That will bond the tape into a single piece of butyl rubber. This should make a long term water-tight connection.

If you want to use a heavier wire, you may delay doing this until you've done the wire upgrade: butyl rubber - which does not harden with time - is hard to remove.

Hope this helps.

Yours faithfully,

Spook