I need to replace the fuel pump on my 960. I've looked up the fuel pump on this car with several parts dealers and without exception they say this car has two fuel pumps. One in the tank and another right before the fuel filter. I can't find the second "In-line" pump anywhere.
My 960 is titled as a 1996 model but the manual that came with it says 1997 - both year models come up as having two pumps. What really concerns me is that if I buy the in-tank pump listed for this car - will it be the right one considering that the same documentation says there are two pumps?
I'm also looking to buy the removal tool to pull the pump retainer ring but the only tool I'm finding online is for the 1998 and up.

What gives?

As Spook already said, there is only ONE fuel pump for your car and it is in the tank. You don't need a special tool to remove the locking ring. The tanks on the 95 thru 98 are the same. I used an iron pry rod about 18 inches long and a hammer to remove the ring.

DEWFPO
--
1998 S90 077,400 and 1995 964 154,100

Dear nondem,

May this find you well. Volvo, as you likely know, is (in)famous for parts variants. Thus, while most 940s have two fuel pumps - an in-tank pre-pump and a main pump on the underside of the floor pan (beneath the driver's seat) - 1995 940s have a single in-tank pump. That in-tank pump is far more powerful than the in-tank pre-pump used on 1991-94 940s.

On 940s and 960s, an externally-mounted main fuel pump will be on a bracket, affixed to the underside of the floor pan, beneath the driver's seat. If it is not present, then your car's fuel delivery system uses a single, in-tank pump.

According to the Volvo Pocket data booklet - Cars: 700,800,900 (1991-1996), use of the pre-pump in 960 series cars was discontinued after 1994. For post-1994 960s, the Volvo part number shown for the fuel pump is 9135418-3. The Bosch part number is 0 580 453 033. Unless I'm mistaken, this Bosch pump is of the same format (dimensions and shape) as the main pump used in models produced up to 1994. This pump will be about 2" inches in diameter and about 7" long. I do not think it will work in your car.

Volvo VADIS, the now-superseded parts and service system - shows Part #9438756, as the in-tank fuel pump for 1995 and later 960s. I'd guess this pump will be about 1.5" in diameter and about 5" long. As VADIS post-dates the Pocket data booklet publication, I'd be inclined to rely on VADIS.

Find out from your nearest dealer, whether they can use your car's Vehicle Identification Number, to ascertain which fuel pump will fit. Before they order anything, ask them if you can decline to accept delivery, if the pump offered to you is not the correct item. They should be willing to do this. Once you take delivery, they will likely not accept a return.

Hope this helps.

Yours faithfully,

Spook

Your Volvo dealer should be able to