I'm replacing the fuel tank in my 77 wagon. The fuel pump is outside the tank and the tank is slightly different than the later model 240. The sending unit is completely different and I kinda broke it taking it off(I can repair it) and it's a different size. I can't find a new sending unit for the year but I can find a tank that is the same. Should I just get a new later model tank and sending unit?

Hello,

I replaced the fuel tank on a customers 1977 264 so I've been through this and it's a major hassle because an accurate reproduction fuel tank isn't available.

I believe you can update to the later tank, but you have to replace just about everything including the fuel filler neck and fuel cap.

The customer opted for the reproduction version of the original fuel tank and this repro is a royal piece of s^&t. This tank lacks several features of the original, but I went ahead and installed it right out of the box and immediately ran into problems.

To begin with, the repro didn't have the "fuel bowl" that is welded inside to the bottom of the tank directly below the fuel pick up tube which is attached to the fuel sender. So when the tank got low on fuel, it sucked air into the fuel pump during turns, quick acceleration or stopping suddenly causing the engine to stumble and drastically lose power.

Next, the repro tank was hard to fill at the gas station and this was due to the missing tank venting system that Volvo incorporated into the fuel filler neck and filler tube section of the tank.

The last issue is the lack of an internal expansion tank. The original Volvo gas tanks have a plastic tank inside and it has a function which is help keep liquid fuel from being sucked into the evap system.

To make the car drive-able, I had to modify the repro tank. I had a fuel bowl and the tube to accept the venting system installed by a gas tank repair shop in the repro tank.

I did not have an expansion tank installed inside as I couldn't figure out an inexpensive fix. The customer was advised not to top off the gas tank especially on hot days.

FYI, I would normally suggest having fuel tanks repaired using a ReNu gas tank repair franchise, but they can't fix the tanks because of the plastic expansion tank Volvo put inside.
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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com

yes, get the whole thing, from cap to fuel tank. you'll have to fake it because the newer tanks don't have a way to hang the main pump next to it. the later cars had a tray in front of the tank to support the pump and accumulator. if your car got the recall back in the day, it would look just like the 78-up tanks, etc. look for a 78-82 240 or an 81-85 240 turbo for the other parts. some 82s had lh1 injection, all 83-up non turbos got lh2. the lh cars won't work for kjet, except for the tank, neck and sender. good luck, chuck.