In-Tank Pump

WARNING: Disconnect battery ground strap before beginning to work on the fuel/electrical system. Do not smoke or have anything in the area which can ignite or cause sparks.

REMOVAL
1. Drain enough fuel from tank to prevent spilling, if tank is over-filled. Use suitable pumping equipment.
2. Remove floor mat and panel from trunk.





3. Disconnect wiring harness connector to sending unit. Remove wires from connector.
4. Disconnect ground wire to sender. Push wires through grommet.
5. Remove cover for access to tank sending unit.





NOTE: Station wagons only: To gain access to the sending unit cover, fold rear seat forward, remove front mat in luggage compartment. Remove three screws, pull mat forward.





6. All models: Disconnect from the fuel tank sending unit:
a. Breather hose C
b. Return hose A
c. Supply hose B
d. Filler hose D
e. Wiring harness from clip E





7. Clean area and unscrew fuel tank sender/pump cap using Volvo Tool P/N 9995448-9. Remove tank sender/pump and seal.
8. Remove pump from sender/pump assembly.





INSTALLATION
1. Inspect the pump for damage, feed pump hose and wiring for wear. Replace as needed.
2. Install new pump to sender/pump assembly.
3. Install rubber seal in neck of tank. Lubricate inside of seal.





4. Install fuel tank sender/pump unit. Align it with the moulded joint (arrows) on tank.
5. Apply rustproofing compound to exposed metal portions of tank sender.

CAUTION: With tape or rubber caps, protect fuel sender openings from overspray.

6. Hand-tighten fuel tank sender/pump to:

22 ft-lb (30 Nm)

7. Reassemble components in reverse order. Use tie straps to secure all hoses and wiring.