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This may have been answered before but what are the setups for fuel pumps in naturally aspirated 940s?
I have changed several in-tank pumps which I believe were the Regina setups. The filter was under the car.
I also have a 1994 which has the Bosch pump and filter under the car. How can I tell if there is another pump in the tank?
One of the part places lists fuel pumps through 1994. Was there a different pump type and setup for 1995s?
Thank you
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Mine:3-940s running; dtrs:4-940s running
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Dear jd620,
Hope you're well and stay so! Cars with Bosch engine/ignition management have a cylindrical ignition coil mounted on the passenger's side of the engine bay, near the strut tower brace.
In all cases, the fuel filter is mounted externally, on the under-body, beneath the driver's seat.
Up to and including 1994 models, Bosch used two fuel pumps. One is an in-tank pre-pump. The second, main pump, is mounted externally, on the under-body on the driver's side, next to the fuel filter. In 1995, cars with Bosch engine/ignition management had a single, in-tank fuel pump.
940s with Rex-Regina engine-ignition management have a rectangular ignition coil, mounted on the front face of the driver's side strut tower. These cars have a single, in-tank fuel pump.
Hope this helps.
Yours faithfully,
Spook
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Thanks Spook. Roughly, what is the life expectancy of the in-tank Regina and Bosch pre-fuel pumps? They are not fun to replace. I have replaced 2 in sedans and 1 in a wagon, all Regina.
Also, there are two types of Bosch in-tank pumps in the 1995s. Something to do with the fuel sender. My daughter's 1995 fuel level fluctuates when she is driving. I'm wondering if there was a replacement to fix that problem.
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Mine:3-940s running; dtrs:4-940s running
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I’m rather familiar with erratic fuel gauge problems in the ‘95 940s, seemingly in particular the turbos. The fuel pickup assembly has a longer barrel and the fuel level sender is a slightly different design from earlier 700/900s with the smaller tank. The float rides between two sensor coil rods. The metal contacts on the float are a butterfly shape and the wings can wear out leaving a jagged edge that catches on the coils and at times may not floating properly thus giving incorrect readings. The resistance wire on the coils is progressively wound. Initially it tends to catch at the top and gives inconsistent readings as the fuel level drops, either freeing itself by its own weight or driving over a bump. After a while the problems start happening at lower fuel levels.
I’ve long suspected this wear is accelrated or made worse on cars that live on rough roads, such as gravel, as I was told the first owner of my turbo did and as confirmed by the shotgun of paint nicks on the front edge of the hood.
The pickup assemblies are expensive and NLA n the parts chain, so you need to find a good used one from a lower mileage '95 940. I'd have to check if the '94 turbos also got the larger tank, but I recall not. I did a crude repair rebuilding the contacts by clipping tabs on the stubs of the wings that has now lasted over 15 years, but over the past 6 months it’s started acting up again. One of these days the fuel pump will go and I'll break open the sender barrel to see what's happened. Cracking open the barrels is not trivial and not for the faint of heart as you risk breaking it plus you can cause permanent damage as well when handling the coil rods.
For whatever reason this has yet to happen on my other ‘95 940 that’s also Bosch single pump with even higher mileage, just crossed 400K km the other day.
As for longevity. I have had to replace the pump once on that NA at about 300K km, but the turbo is still on the original pump at 375K km. I was hesitant to put in the smaller aftermarket Waller/Helbro pump that is significantly cheaper than the Bosch original, but at 100K km it seems fine. Pumps are also known to last longer if you drive around mostly with a full tank rather than empty due to both cooling being immersed in fuel and also the greater lift for the pump..
I vaguely recall any difference between the NA in-tank pump and the turbo pump is the working pressure spec.
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Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now
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Thanks Dave. His some info. I got from the IPD web site on the 2 NA 1995 940s Bosch fuel pumps. I wonder what the difference is? Note the comment about Bosch In-tank w/ Original fuel sender. I wonder if the second pump below fixed the problem you mentioned or ??:
1995 VOLVO 940 NON-TURBO 900 4 DR SEDAN B230F LH 2.4 AW71 RWD
Genuine Volvo - 9438756, 9135605, 9438002, 9438003 Bosch In-tank w/ Original fuel sender
Year Make Model Trim Chassis Bodystyle Engine Fuelsys Drive Transmission
1995 VOLVO 940 NON-TURBO 900 4 DR SEDAN B230F LH 2.4 RWD AW71
1995 VOLVO 940 NON-TURBO 900 5 DR WAGON B230F LH 2.4 RWD AW71
1995 VOLVO 940 NON-TURBO 900 4 DR SEDAN B230F LH 2.4 AW71 RWD
Genuine Volvo - 9445444, 9438001 Bosch
Year Make Model Trim Chassis Bodystyle Engine Fuelsys Drive Transmission
1995 VOLVO 940 NON-TURBO 900 4 DR SEDAN B230F LH 2.4 RWD AW71
1995 VOLVO 940 NON-TURBO 900 5 DR WAGON B230F LH 2.4 RWD AW71
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Mine:3-940s running; dtrs:4-940s running
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9445444 is the NA fuel pump for B230FD w/Bosch main in-tank pump
9438756 is the turbo pump for B230FT w/Bosch main in-tank pump
I checked my notes and the turbo pump is higher flow.
(the IPD listing is incorrect and I can see a Volvo fitment listed elsewhere they may have used where the fitment is listed for both, but the description correctly says for turbo only).
I'm going over some old notes trying to sort out the various tanks and fuel pickup assemblies for the 940s. Turns out much of those notes made it into the FAQ here about the various tanks, senders and pumps:
https://www.brickboard.com/FAQ/700-900/FuelSystem.htm#FuelPumpandSenderReplacement
Checking a bit further into this, it seems that troublesome fuel pickup assembly (also called the fuel feed unit and/or sender unit) with the float contacts that wear is p/n 9412950 with fitment specific to the '95 940 turbos. You have to be careful with p/n's for this unit as some include the fuel pump.
I'm having problems finding the p/n for the B230FD NA sender unit. My visual recollection is that it was the same as the turbo in all regards other than the pump mounting bracket. One of the differences between the senders for the later large tanks compared to the earlier 940 tanks is that they support the warning light in the dash gauge when the coil resistance becomes great and indicates the tank is getting empty.
If your daughter's 940 is NA and has fuel gauge issues then if it's not that troublesome float contact (presuming it's a different design from the turbo one I bust open) then you need to think about checking for damage at the tank wiring connector and then start thinking about poor grounds, such as at the tank and especially in the instrument cluster. The pump itself should of course not affect the gauge. Pumps can fail in a couple of ways, but mostly they may simply go dead and no longer run at (cold) startup or else can wear out, overheat and start seizing up under extended use, especially at full fuel load.
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Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now
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Dear Dave Stevens,
Hope you're well and stay so. According to the Volvo Pocket data booklet - Cars (700, 850, 900) 1991-1995, fuel tank capacity for 940s (Sedans and Wagons), 1993-1995 was 75 liters. For 960s, the tank capacity was 80 liters, except for the 960 wagon (1993-94), which had a 75-liter tank. Send units from 1992 and earlier models will fit in 1993 and later cars, but have a barrel too short to reach the bottom of the larger tanks, so will not be able to use all of the fuel in the tank.
As to fuel pumps, the pre-pumps used in 1993-94 normally-aspirated 940s draw 3-4 Amps; pre-pumps in turbos draw 5.5 Amps. As to main pumps - whether mounted externally or in the fuel tank and whether turbo or normally-aspirated - all have the same capacity: 130 liters/hours at 12 volts and all draw 6.5 Amps.
Thus, while there are several part numbers for these pumps - both Bosch and Volvo - the pumps seem identical in terms of their capacity to move fuel.
I've replaced a Rex-Regina fuel pump and send unit at 141K miles and a '95 940 fuel pump and send unit at 71K miles; the pump was fine but the send unit was not reliable.
Hope this helps.
Yours faithfully,
Spook
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Hi Spook, Re. the Bosch in-tank main fuel pumps for 940s.
According to the Volvo Pocket Data Book (which agrees with my understanding), these were used only in the 1995 models (1995-on 940 in non-North American market, while in other markets it would be '95-'97), while earlier 940s with B230F Regina used a different single main in-tank pump and all other eariler B230F/FD/FT and B234F with Bosch injection were an external main pump with an in-tank pre-pump, similar to the 740s and 240s.
Yes, I see what you're saying about 1995 fuel pump specs from the Pocket Data Book:
o For 1995-on B230FD NA the Bosch p/n was 0580253033 (Volvo p/n 935418) with a pump capacity of delivering 130 litres/hr at a system pressure of 300 kPa making for a draw of 6.5 amps at 12 volts at 20 degC (room temp).
o For 1995-on B230FT turbo the Bosch p/n was 058453037 (Volvo p/n 9136605) and the same specs for delivery under the same conditions.
I note in pics on websites that these are identical looking pumps, also they appear to mount the same on the sender barrel. Despite notes I may have had and in the FAQ, it makes sense to me and I'm now working under the assumption that all 940s that got the larger 73 litre tank used the same longer barrelled fuel pickup/sender assembly. Whether the pump mounting brackets are slightly different is another matter. I've had both sender units out of my '95 940 NA and turbo and my recollection is that they were the same and used the twin coil rod fuel level sender (the one with the butterfly contacts that can wear out as I described), rather than the single coil rod design used in the earlier shorter-barrelled sender units. And, yes, a 740 sender fits the larger tanks for collar size and thread, but the dash gauge will read extremely incorrectly and the bottom 1/4 of the tank will not get used -the end only partially extends into the central anti-slosh bucket and will suck air easier accelerating up or down hill with a 1/4 full tank.)
So that now begs the question, why two different pumps for NA and turbo that externally look identical and appear to have the same specs? (Also priced very close in listings.) About the only difference I'm aware of between these these two fuel delivery systems is the injectors, with the NA injector delivering 185 cc/min and the turbo injectors delivering 300 cc/min (the 16-valve B234F is in between at 214 cc/min). The fuel system pressure is the same at 300 kPa (both use the same pressure regulator). So, as much as the bench specs are the same for the two pumps and unless there is an external physical difference (which I maintain there isn't) then all I can assunme is that the turbo pump must somehow be designed to better maintain that 300 kPa fuel rail pressure under higher flow rate conditions, hence my note that one is a high flow pump. That also begs the question, why not just use the same turbo pump in the NA engine?
I'll also mention all the fuel pump p/ns in the Pocket Data have since been superseded, so the pump specs may or may not be as published.
To come at this a second way, we can refer to the current genuine Bosch Automotive catalog and their current vehicle selector fitments. For '95 940s, three pumps are listed:
o Bosch p/n 69593 is for the B230F (Volvo OEM p/n 9142044, supercedes p/n 1389449).
o Bosch p/n 69594 is for the B230FT (Volvo OEM p/n Volvo 9142045).
o Bosch p/n 69693 is also listed for the B230FT, which if you do additional research turns out to be 69594 with the filter sock (strainer) included. None of these pumps include mounting clamps or have differecnt connections, which might have explained different p/ns.
Unfortunately, my trail ran dry there for what the differences actually are inside these two Bosch pumps.
To come at this a third way, which now starts to get confusing, we can do a vehicle selector lookup on the various Genuine Volvo dealer distributor parts suppliers (most pull up the same or similar schematics). Using part descriptions, for '95 940 the NA pump is now Volvo p/n 9445444 and the turbo pump now p/n 94338756. Neither of those matches p/n's mentioned above. However, when you lookup the fitments for each of these pumps, mysteriously the NA pump is also listed for turbos.
Things can get even messier when you start to lookup aftermarket suppliers of the Bosch pumps using vehicle selectors and then calling up their fitments, also attempting to figure out the cross references to equivalent Volvo p/n's.
Bottom line, in my mind there's still a bit of unsolved mystery here. Suffice it to say all these pumps appear to be identical in pics and I've found no description that explains the difference. It wouldn't surprise me if both pumps could be used in either the '95 B230FD or B230FT, just that the turbo pump may somehow be more appropriate for the job under demanding conditions. Based on what I know at the moment, if and when I need a new in-tank main pump for my '95 Bosch turbo then I'd use the Bosch fitments, which just happens to be the pumps available at RockAuto and the best buys around.
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Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now
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