Question about 1995 Volvo 940

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I need to replace the fuel pump in my 940 Volvo.

I need to replace the fuel pump in my 1995 940 Volvo. I have the part, but am unsure how to actually make the replacement. Does anyone have any guidance? The local mechanics want to charge around 800 to do the replacement, and that's more than I'm willing to pay. Thanks for any help.

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  • Anonymous Mar 14, 2014

    Volvo 940

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  • Volvo Master
  • 545 Answers

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

  1. Drain enough fuel from tank to prevent spilling, no more than 4 gallons (16 liters) of fuel should remain. Use suitable pumping equipment.
  2. Remove floor mat and panel from trunk.
  1. Disconnect wiring harness connector to sending unit. Remove wires from connector.
  2. Disconnect ground wire to sender. Push wires through grommet.
  3. Remove cover for access to tank sending unit.
  1. All models: Disconnect from the fuel tank sending unit:
    1. Breather hose C
    2. Return hose A
    3. Supply hose B
    4. Filler hose D
    5. Wiring harness from clip E
  1. Clean area and unscrew fuel tank sender/pump cap or equivalent. Remove tank sender/pump and seal.
  2. 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.
  1. Install fuel tank sender/pump unit. Align it with the moulded joint (arrows) on tank.
  2. Apply rustproofing compound to exposed metal portions of tank sender.
CAUTION : With tape or rubber caps, protect fuel sender openings from overspray.
  1. Torque fuel tank sender/pump lock ring to: 22 ft-lb (30 Nm)
  2. Reassemble components in reverse order. Use tie straps to secure all hoses and wiring.

Posted on Jun 04, 2009

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Posted on Jan 02, 2017

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