Fuel Pump Unit, Replacing: Notes

WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.

Special tools:

9812270

9812273

Safety

First see Safety Regulations For Handling Fuel .

Preparation

Draining the fuel tank

To drain the fuel tank, see Draining the Fuel Tank AWD and 2WD/ORVR (IE00)

If you have drained the fuel tank according to the "non working fuel pump" method continue according to Fitting the Fuel Pump Units and then Fitting the Rear Suspension Assembly .

Draining the fuel system

To drain the fuel system, see Draining Fuel Injection System .

Removing the luggage compartment floor

Fig 1: Identifying Fasteners On Cargo Compartment Floor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the front and rear luggage compartment floor.

Unplugging the connectors

Fig 2: Identifying Front Cover And Connectors For ABS Sensor And Fuel Level Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Undo the ABS sensor and fuel level sensor connectors.

Remove the connectors' holder and the front cover.

Feed the leads through the hole.

Detaching the filler pipe

Fig 3: Identifying Filler Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the lock ring from the rubber gaiter.

Press the rubber gaiter and filler pipe into the wheel housing.

Disconnecting the rear wheels

Fig 4: Identifying Wheel Arch Liner And Mudflap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove:

rear wheels
right-hand wheel arch liner and mudflap.

Disconnecting the fuel tank EVAP lines

Fig 5: Identifying Fuel Lines, Plastic Clip, And Protective Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the protective cover from the fuel lines.

Removing the protective covers in front of fuel tank

Remove:

protective covers at front edge of fuel tank (three plastic nuts on each cover)
all pipes from the plastic clips on the fuel tank.

Removing the exhaust pipe

Fig 6: Identifying Rear Exhaust Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the rear exhaust pipe and silencers.

Detaching the longitudinal stay mountings

Fig 7: Positioning Engine Lift Against Longitudinal Stay Mounting

Courtesy of VOLVO CARS OF NORTH AMERICA.

Detach the longitudinal stay mountings from the body.

Position an engine lift gently against the longitudinal stay mounting.

Remove:

bolts for jack attachment and longitudinal stay mounting in body, both sides
engine lift.

Undo:

three-way branching on left-hand jack attachment.
front brake pipe from the 4 clips under the car.

Removing the hand brake cable

Fig 8: Identifying Pop Rivet And Cable Tie At Jack Attachment/Longitudinal Stay Brackets

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the hand brake cable from the jack attachment by drilling out the pop rivet (B).

Tie the jack attachment to the longitudinal stay brackets (A). Use a cable tie.

Removing the propeller shaft

Fig 9: Identifying Propeller Shaft Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Mark the propeller shaft in relation to the driver.

NOTE: Note the bolt length and location on the CV joint. See the table below (standard bolts for front and rear CV joints and balancing bolts for rear joint).

Remove the propeller shaft bolts. Use holding tool 9995561 . Move the shaft to one side.

Standard bolts for front and rear CV joints and balancer bolt for rear CV joint

NOTE: Before removing the propeller shaft from the companion flange: Carefully mark the position of the propeller shaft in relation to the companion flange. Check also whether balancer bolts are fitted. Where applicable, note the position and length of the balancer bolts.

Standard bolts	length 50 mm	red marking (lock paint)
Balancer bolts	length 52.5 mm	white marking (lock paint)
Balancer bolts	length 55 mm	blue marking (lock paint)
Balancer bolts	length 57.5 mm	black marking (lock paint)
Balancer bolts	length 60 mm	yellow marking (lock paint)
Balancer bolts	length 62.5 mm	grey marking (lock paint)
Balancer bolts	length 65 mm	green marking (lock paint)
Balancer bolts	length 70 mm	red marking (lock paint)

NOTE: If the previous propeller shaft is refitted without replacement of the rear joint or removal or replacement of the companion flange on the differential, perform the following: fit the propeller shaft using the markings made upon removal. Use new bolts of the same length as those removed. If the propeller shaft is to be changed, the new shaft must be fitted with new bolts of standard length.

Lowering the torque tube

Fig 10: Positioning Jack Against Torque Tube

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position the jack 9985972 against the torque tube.

Remove the bolt and lower the torque tube with the engine lift.