changing the in tank fuel pump on a 240 SW

Discussion in 'Volvo 240' started by Marco Rolandi, May 24, 2004.

  1. Hello,

    I have an '83 240 Gl SW with 180K that is running great.
    The in tank fuel pump becomes rather noisy if the tank is less than 1/2
    full, so I decided to change it.

    I encountered couple of problems.

    1 The Hayes manual tells you to depressurise the system by removing the
    fuses for both fuel pumps while the engine is running and let it stall.
    Regardless of which fuses I take out the main fuel pump keeps on running
    and the engine never stalls. Is there an easy way to disconnect the pump??

    2 I attempted to remove the hoses from the in tank pump, but I had
    troubles. One just does not come out and it feels like the system is under
    vacuum. Is there any way that I can completely get rid of the vacuum?? Or
    do I just have to pull on it harder??

    Marco Rolandi, May 24, 2004
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  2. Marco Rolandi

    Mike F Guest

    One hose is attached to the top of the sender unit permanently, the
    connection is about 50 cm away.

    Mike F.
    Thornhill (near Toronto), Ont.

    NOTE: new address!!
    Replace tt with t (twice!) and remove parentheses to email me directly.
    (But I check the newsgroup more often than this email address.)
    Mike F, May 25, 2004
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  3. Marco Rolandi

    Rojo2G Guest

    I decided to change it.
    I just changed both fuel pumps in my 83 wagon recently(like three weeks ago).
    The toughest part was removing and reinstalling the filler tube. There is a
    collar on the left side of the back that you reach by angling your arm between
    the body and the gas tank. It took a 10mm wrench.
    I took out the tank and was glad I did since it was very easy and five bolts.
    The two fuel hoses on top of the tank I seperated from the tank inside the car.
    If the hose was stuck I would have, in a difficult case, try to work soapy
    water between the hose and metal tube.
    Disconnect the battery of course.
    The electrical connection, I disconnected at the connector on the body and let
    it flop with the tank when I took it out. I don't think it will seperate from
    the tank access when changing the intank fuel pump.
    I cleaned up the tank access really well using WD 4o and then tapped it open(
    it only goes one way) with a solid brass piece of metal. It came off with
    surprisingly easy taps. The inserted fuel gauge and fuel pump had to be
    manuerved carefully which is one reason I was glad to remove the tank.
    Ok, if there was a vaccum I would think that removing the gas cap would solve
    that problem. You could also remove the hose at the main fuel pump. Mine has a
    screw clamp holding it on,
    It seems a daunting task but the only weary part was taking and reinstalling
    the filler hose collar.
    Rojo2G, May 26, 2004
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