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Tips on replacing intank fuel pump.

I am about to replace the intank fuel pump (only one on the 95 940). Any hints on the job? I am a little worried about working around a giant open container of gasoline.

I got a used fuel pump - 40 dollars versus the 400 dollars from a dealer. Apparently Volvo changed the fuel pump design (or sender not sure which one)- but anyways the old sender is apparently not compatible with the new fuel pump available through Volvo. I only had the tank open for a short time and it was apparent how the fuel pump is physically connected to the wires. Any hints?

Thanks-
Charles








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    Tips on replacing intank fuel pump.

    I've done this job on my 93, it's the Regina or GM crappo fuel pump. No smoking while doing this job, tank and other stuff is plastic, so chance of spark is low, keep garage door open, if possible, although it was a winter when I did mine and door was closed.

    This puppy is quite tricky to get out of the hole, you need to twist and pull or pull and twist while holding extension up or down. Sorry, but I can't remember the whole routine, but patience is a must for this one. If you start getting ticked off, walk away for a while. As for the rubber seal, you either put it in the hole and slide unit in or put in on the unit and slide it in. It goes in real easy one way, but real hard the other, it will be obvious. Disconnecting the lines and re-connecting them is straightforward.

    For what it's worth, this is not a job where you want to go used. These GM pumps aren't the greatest to begin with, and I doubt you'll want to repeat this job in 3 months. But, if you still want to go used, you'll have to solder the connections once your pump is installed on the sender. Again, personally, I'd go with a new pump on your sender if money really is the issue, or better yet a complete new unit ($$). This will make sense once you get started on this. Good luck.

    Mike








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      Tips on replacing intank fuel pump.

      The fuel pump is a bosche unit - I don't have the regina system. The procedure I'm sure is the same though. I am not looking forward to the soldering and I suspect I'll want to solder far from the 17 gallons of gas in an open container. I'll need to rig something to cover the hole.








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    Tips on replacing intank fuel pump.

    Can't help from experience but I've paid attention to this question in case I have to do it on my '93 940. There was a thread which discussed the difficulty in getting the assembly back into the tank. It needed to go in at just the right angle and then turn. There was also a difficulty in seating the assembly and locking it against the pressure of the rubber sealing ring. Try a search on this site. there were several threads on this with help in these difficulties.

    I can definitely say to put out your cigar while doing this!







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