Question about 1994 Volvo 940

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The fuel pump has ben taken apart

My father took apart his volvo 1994 940's fuel pump and doesnt know how to put it back together. Could you help us out?

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  • Volvo Master
  • 6,826 Answers

REMOVAL & INSTALLATION 2.3L 4-Cylinder and 2.8L 6-Cylinder Engines

  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Raise and support the vehicle safely.
  4. Remove the fuel tank.
  5. Loosen the lock ring at the top of the fuel tank and remove the sending unit with the transfer pump attached. Note the direction of the float in the tank.
  6. Remove the transfer pump from the sending unit. To install:
  7. Install the transfer pump on the sending unit.
  8. Install the sending unit in the fuel tank and tighten the lock ring to specification. Do not overtighten the lock ring as the plastic threads on some fuel tanks are easily stripped.
  9. Install the fuel tank in the vehicle.
  10. Lower the vehicle.
  11. Connect the negative battery cable.
  12. Start the engine and check for leaks. Fig. 1: Fuel pump assembly for the 2.3L 4-cylinder engine the fuel pump has ben taken apart - 90955g07.gif
    Fig. 2: Fuel pump assembly for the 2.8L 6-cylinder engine 90955g17.gif
2.3L and 2.4L 5-Cylinder, and 2.9L 6-Cylinder Engines
  1. Relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Tilt the rear seat forward and remove or fold back the trunk compartment carpet over the right-hand wheel well panel.
  4. Disconnect the fuel pump electrical connections. NOTE: Take note of the color markings on the hoses; colored tape should identify hose locations on the pump.
  5. Detach the quick-connect couplers for the fuel delivery and return hoses.
  6. Remove the pump unit by unscrewing the retaining nut using tool 999-5485 or equivalent.
  7. Lift the pump out carefully and remove the rubber seal. When lifting the pump out, do not grab the connections with pliers or any other sharp tools that might cause damage and result in fuel leakage. To install: WARNING
    Install the retaining nut while the pump is removed, otherwise the tank connection may swell and the nut will be difficult to install.
  8. Install a new dry seal, making sure that it is seated properly. Lubricate the top and outer side of the seal with petroleum jelly.
  9. Install the pump with the heater connection facing towards the right side of the vehicle.
  10. Install the fuel pump retaining nut and tighten it to 30 ft. lbs. (40 Nm) using tool 999-5484 or equivalent.
  11. Apply a small amount of petroleum jelly to the delivery and return hose ends and install them on the pump. The delivery line is marked with yellow tape, which should be matched to the yellow marked pump outlet. Make sure that the quick-connectors are properly seated on the pump.
  12. Connect the electrical connections, making sure that they are in the correct position. Install the panels and carpets.
  13. Connect the negative battery cable.
  14. Run the engine and check for leaks. Fig. 3: Remove the clips retaining the carpethe fuel pump has ben taken apart - 90955p01.jpgg src="http://i.fixya.net/uploads/images/90955p01.jpg" alt="90955p01.jpg" class="h_mi" />
    Fig. 4:the fuel pump has ben taken apart - 90955p03.jpgpose the fuel pump access cover 90955p03.jpg
    Fig. 5: The rear seatthe fuel pump has ben taken apart - 90955p02.jpgded down from the inside, but this lever must be in the up position
    Fig. 6: Release this lever from inside the car to lower the rear seats 90955p12.jpg
    Fig. 7: Remove the trim retaining bolt from the bthe fuel pump has ben taken apart - 90955p05.jpg panel 90955p04.jpg the fuel pump has ben taken apart - 90955p06.jpgFig. 8: Remove the seat back striker using a T30 Torx® bit
    Fig. 9: Carefully push the trim back . . . 90955p06.jpg
    Fig. 10: . . . to access the fuel pump harness connections the fuel pump has ben taken apart - 90955p09.jpgttp://i.fixya.net/uploads/images/90955p07.jpg" alt="90955p07.jpg" class="h_mi" />
    Fig. 11: Remothe fuel pump has ben taken apart - 90955p10.jpgpump access cover retaining bolts 90955p08.jpg
    Fig. 12: When the cover is removed, the fuel pump is visible
    Fig. 13: Detach the quick-connect fittings . . .
    Fig. 14: . . . and remove the fuel lines from the pump
    Fig. 15: Use wrench 5485 or equivalent to remove the fuel pump retaining the fuel pump has ben taken apart - next.gifmg src="http://i.fixya.net/uploads/images/90955g08.gif" alt="90955g08.gif" class="h_mi" />
    Fig. 16: After the retaining ring is removed, lift the pump out of the tank 90955g09.gif
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Posted on Aug 01, 2010

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