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.