Replacing The Fuel Pump In A 2001 Volvo S80

If you're looking to replace the fuel pump in your 2001 Volvo S80, you'll need to first locate it. In most Volvo S80 models, the fuel pump is situated under the rear seat. To access it, you'll need to remove the rear seat backrest and fold back the floor carpet in the cargo compartment. Once you've done that, you can start disconnecting the fuel pump's connectors and hoses. Be sure to have a new fuel filter on hand, as it's recommended to replace the filter whenever you replace the fuel pump. Additionally, if your fuel pump has failed prematurely, it's a good idea to verify the power supply, as a voltage drop can lead to overheating.

Removing the rear seat backrest

To remove the rear seat backrest of a 2001 Volvo S80, follow these steps:

First, make the necessary preparations. Turn off the ignition. Remove the rear seat backrest and the insulation. Fold back the floor carpet in the cargo compartment.

Next, you will need to drain the fuel tank. To do this, remove the cover over the fuel level sensor. Disconnect the connector. Remove the circlip for the level sensor using a special tool. Pull the level sensor up. This is easier if the fuel lines are bent upwards through the hole. Disconnect the two connectors from the level sensor. Remove the ejector by pressing down on the catch.

Now, you can remove the rear seat backrest. Simply lift it out and set it aside.

With the rear seat backrest removed, you will have access to the fuel pump. It is located under the rear seat, on the right side, on an incline. You may need to remove a black bar to access it.

To replace the fuel pump, you will need to remove the access cover and the two visible nuts. Then, release the right backrest in the trunk and fold it down to access the other two nuts. With these removed, you can completely remove the backrest, which will make it easier to access the fuel pump.

Remember to exercise caution when performing any fuel pump-related work, as gasoline and its vapors are highly flammable.

Draining the fuel tank

To drain the fuel tank of a 2001 Volvo S80, follow these steps:

First, remove the rear seat backrest and the insulation. Fold back the floor carpet in the cargo compartment.

Next, remove the cover over the fuel level sensor. Disconnect the connector. Remove the circlip for the level sensor using a special tool. Pull the level sensor up. This is easier if the fuel lines are bent upwards through the hole. Disconnect the two connectors from the level sensor. Remove the ejector. Press down the catch. Remove the level sensor.

Now, carefully position the level sensor with the pipes and the wiring. Ensure that the float does not catch on the wiring or fuel hoses when installing the level sensor. Install the circlip for the level sensor without tightening it. Press the level sensor into place. Note the position marking on the cover and tank. Tighten the circlip, first by hand, then using a special tool.

Finally, tighten to 60 Nm. Install the cable in the groove on the rubber seal. Connect the connector. Install the cover over the level sensor. Tighten to 60 Nm.

Once the fuel tank is drained, you can proceed to remove the fuel pump.

Removing the fuel level sensor

To remove the fuel level sensor of a 2001 Volvo S80, follow these steps:

First, remove the rear seat backrest and the insulation. Fold back the floor carpet in the cargo compartment. Next, drain the fuel tank. To access the fuel level sensor, remove the cover over it. Disconnect the connector and then remove the circlip for the level sensor using a special tool. Pull the level sensor up, bending the fuel lines upwards through the hole to make this easier. Disconnect the two connectors from the level sensor and remove the ejector by pressing down the catch. Now, the level sensor can be removed.

To install the new fuel level sensor, follow these steps:

Locate the level sensor in the correct position and install a new rubber seal. Lubricate the screw mating surface with petroleum jelly. Connect the two connectors to the level sensor and press the pipes into place. Carefully position the level sensor, ensuring that the float does not catch on the wiring or fuel hoses. Install the circlip for the level sensor without tightening it and press the level sensor into place. Tighten the circlip first by hand, and then use a special tool to tighten it to 60 Nm. Install the cable in the groove on the rubber seal and connect the connector. Install the cover over the level sensor and tighten to 60 Nm. Finally, install the rear seat backrest.

Removing the fuel pump/sender

To remove the fuel pump/sender, you must first remove the rear seat backrest and the insulation. Fold back the floor carpet in the cargo compartment. Then, drain the fuel tank.

To remove the fuel level sensor, remove the cover and disconnect the connector. Remove the circlip for the level sensor using a special tool. Pull the level sensor up, and disconnect the two connectors. Remove the ejector by pressing down the catch.

Now, you can remove the pump/sender. Grip the right-hand level sensor and pump holder and pinch it so that the float is held in its lowest position. Carefully and slowly pull up the holder and work it out. Pull the hoses out from the tank without pulling up the entire string from the right-hand hole in the tank. It is extremely important that the float arm is not broken or bent.

Use the string to pull the hose and wires to the other side of the tank and reinstall the sender.

Reinstalling the sender

To reinstall the sender, follow these steps:

First, locate the level sensor in the correct position. Install a new rubber seal. Use petroleum jelly to lubricate the screw mating surface with the fuel tank unit. This is so that the screw does not turn the fuel tank unit when it is tightened. Connect the two connectors to the level sensor. Press the pipes into place on the level sensor. Carefully position the level sensor with the pipes and the wiring. Ensure that the float does not catch on the wiring or fuel hoses when installing the level sensor.

Next, install the circlip for the level sensor without tightening it. Press the level sensor into place. Note the position marking on the cover and tank. Tighten the circlip, first by hand, then using a special tool. Tighten to 60 Nm. Install the cable in the groove on the rubber seal. Connect the connector. Install the cover over the level sensor. Tighten to 60 Nm.

Finally, install the rear seat backrest.

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