Genuine Volvo 960 Fuel Pump

Volvo 960 Fuel Pump Parts and Q&A

• Fuel Pump
  3501928
  Q: How to remove and install the Fuel Pump and fuel system components on Volvo 960?

  A:

  For 2.3L and 2.8L 4-Cylinder and 6-Cylinder engines, respectively, to remove and install the fuel system components, you must first relieve the fuel system pressure and disconnect the negative battery cable. Safely hoist and support the vehicle, and then drain the Fuel Tank. Loosen the lock ring at the top of the fuel tank, and remove the sending unit with the transfer pump attached, making note of the direction of the float. Dismantle the transfer pump from the sending unit. Installation: For installation, attach the transfer pump to the sending unit, put the sending unit back in fuel tank and tighten the lock ring but don't overtighten. Reinstall the fuel tank, lower the vehicle, reconnect the negative battery cable, and start the engine to check whether there are any leaks. For 2.3L and 2.4L 5-Cylinder, and 2.9L 6-Cylinder engines, relieve the fuel system pressure and that disconnect the negative battery cable. Tilt the seat in the rear to the forward position and take the carpet over the trunk compartment out of the trunk over the right-hand wheel well panel, and disconnect the fuel pump electrical connections and note the color markings on the power hoses. Remove the quick-connect couplings on the fuel delivery and return hoses and remove the pump unit by unscrewing the retaining nut with the proper tool. Carefully lift the pump out without damaging connections by removing the rubber seal. For installation, place a new dry seal, lubricate and install the pump with the heater connection facing the right of the vehicle. Tighten the fuel pump retaining nut to the specified torque, apply petroleum jelly to the ends of the hoses, and connect the hoses to the pump making sure the quick-connectors are seated well. Reconnect the electrical connections, reinstall the panels and carpets, reconnect the negative battery cable and run the engine checking for leaks. For pressure testing, release the fuel pressure, and connect a fuel pressure gauge between the fuel line and distribution manifold or Schrader valve using a shop towel to catch any spilled fuel. On 700 and 900 Series vehicles, you can remove the seat belt reminder for easier testing. Start up the fuel pump by connecting a jumper lead between the terminals on the relay socket and check on fuel pump operation by listening at the fuel cap. Note the reading on the gauge, it should be about 43.5 psi then remove the jumper lead and relieve the fuel system pressure then take out the pressure gauge before putting the fuel pump relay back in.