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Intank replacement experience 900 1994

posted by  rstarkie on  Sun Feb 3 05:31 CST 2008
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last visit: Fri Oct 24 10:14 CST 2014
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1994 944T 175K

The current project car had a main pump that was noisey and as expected it was because the intank pump had died.

I have done about five journeys into the fuel tanks of the 740/940 series and this was the most difficult to date.

For starters Volvo at some point started using plastic inserts for the four screws that hold the access door in place. At the time of assembly it was quick and easy for the worker to push inserts into the square holes and after placing the door simply add the screws to draw it down. However, after fourteen years of exposure to the elements the screw threads had corroded some and the plastic had gotten brittle. Two of the screws came out and two had the plastic break off and spin making them impossible to remove without cutting the heads off with a die grinder. The process added some time to the job.

I also had a very difficult time getting the intank unit turned properly for removal and an even more difficult time getting the unit rotated to the proper position so I could get the locking ring back in place when I was putting it back together. Perhaps Volvo changed the bottom of the tank configuration in the later years? It seemed to be hanging up on something on the bottom of the tank.

Another change from my previous experiences was the length of the fuel hose that connects the intank pump to the pickup. The fuel hose is about 12” long compared to the 3” piece that I am used to. Since the proper hose is not something you usually have on the shelf it would be to your advantage to get that before starting the job. Any one know when that change came about?

After replacement the main pump is nice and quiet.







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    Intank replacement experience 900 1994

    posted by  Dave Stevens on  Mon Feb 4 13:33 CST 2008
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    last visit: Sun Jan 1 02:36 CST 2012
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    Too bad you didn't know about some of this earlier, Randy.

    The 94-95 940s, leastwise the turbo's, got a larger 73 litre tank that used a new, 1-1/2" longer, spring loaded sliding barrel pick-up assembly with the main pump on it (turbo and NA pumps different). Getting it out wasn't overly horrid for me compared to the older 700 assemblies as long as I followed my own instructions (in the FAQ I believe), but getting it back in just wasn't going to happen easily. The trick is to loop string (fishing line is excellent) down around the pump so you can pull back and retract the spring loaded barrel while you twist the assembly into the tank and get the end into the anti-splash bucket in the bottom of the tank. Then you let go of one end of the loop and pull the string out. You can then bump the assembly into final alignment and push the unit down into the collar.

    In case you haven't been down this road, the big plastic locking ring is only supposed to be hand tight (or maybe 1/8 to 1/4 turn more max) otherwise you risk jumping and/or stripping the threads, allowing a leak. Also, your year should have come with a loose metal ring clamp to go around the locking ring, making for a more positive seal. If you have it partially tight when starting, it reduces the chance of jumping and stripping threads. When doing this job on any 700 or 900 that uses a plastic locking ring, I strongly recommend using a metal ring clamp (go to Home Depot or wherever and get yourself a 5", as I recall, stainless steel ring clamp). To check for leaks, fill the tank right up and drive around for a few days choosing places to park at odd angles. If you smell gas then the locking ring isn't properly sealed meaning the top of the assembly isn't properly seated. It's easy to end up with it seated at a slight angle and I always do a careful visual check for an even gap under the locking ring before closing up shop.

    Now, don't you just wish you'd poked around here some more?
    --
    Dave -940's, prev 740/240/140/120 You'd think I'd have learned by now








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      Intank replacement experience 900 1994

      posted by  rstarkie on  Mon Feb 4 15:03 CST 2008
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      last visit: Fri Oct 24 10:14 CST 2014
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      Poking around here a little more would have prevented having to do so much poking around in the trunk learning new off color word strings....(grin)

      I was careful in getting the locking ring started correctly as it wanted to cross thread numerous times.

      The car is definitely a long term project and it will be some time before I will have the opportunity to fill the tank and smell for leaks.

      Thanks for the response.

      Randy







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