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Jerry
Jerry, Master Mechanic
Category: Volvo
Satisfied Customers: 17165
Experience:  ASE Master, shop owner, 30+ years all makes and models
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How do you replace a fuel pump on a 1995 volvo 960

Customer Question

how do you replace a fuel pump on a 1995 volvo 960
Submitted: 8 years ago.
Category: Volvo
Expert:  Jerry replied 8 years ago.

Hello and welcome to Just answer.com, Super mechanic here. About your vehicle.

 

FUEL PUMP REPLACEMENT

 

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4-Door Models:

  • Remove:
  • Spare wheel cover.
  • Trunk floor carpeting.

 

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5-Door Models:

  • Remove:
  • Left rear wheel-arch cover.
  • Floor panel behind rear seat. (Fold down seatback to reach nuts and then draw panel forwards and upwards).

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Remove:

  • Tank unit cover. Clean around tank unit and hose connections.
  • Hoses from tank unit. (Remove quick-release coupling by simultaneously pressure on hose and sliding sleeve upwards).

NOTE: Wear a mask to avoid inhaling fuel vapor.

 

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Remove:

  • Hose clips around nut.
  • Nut to tank unit with tool P/N(NNN) NNN-NNNN
  • Lift up tank unit as far as electrical leads allow.
  • Seals.

NOTE: If tank nut is not replaced within about half a day, It must be changed or it will not fit and leakage will result.

 

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Slack Off Pump

  • First detach lower pump fastener then upper fastener.
  • Disconnect electrical leads.
  • Slack off hose clip at pump.
  • Carefully remove pump from hose.
  • Change pump.

Fit:

  • Pump electrical wiring.
  • Pump to hose and tighten hose clip.
  • Attach upper fastener first.
  • Press in lower fastener.

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Fit Tank Unit

  • Fit new seal to tank opening.
  • Grease tank unit contact surface with a thin layer of petroleum Jelly (glycerol).
  • Lower tank unit into tank, taking care not to damage pump fixings against tank wash-plates. Check that seal is not drawn into tank.

 

 

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Locate Tank Unit

  • Locate position marks against tank plastic joints.
  • Enter nut and tighten with tool P/N(NNN) NNN-NNNN taking care not to damage nipples.
  • Lock with hose clip.

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Fit:

  • Hoses. Check that hoses cannot slip off pipes on tank unit.
  • Tank unit cover.

 

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Carry Out Function Check

  • Check pump and measurement functions.

 

 

 

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4-Door Models:

  • Fit:
  • Spare wheel cover.
  • Trunk floor carpeting.

5-Door Models:

  • Fit:
  • Left rear wheel-arch cover.
  • Floor panel behind rear seat.

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