Replacing Fuel Pump In 2001 Volvo S60: Step-By-Step Guide

Changing the fuel pump on a 2001 Volvo S60 can be a challenging task. It requires removing the passenger-side rear seat back, unhooking the fuel lines, and carefully pulling out the sending unit while managing the fuel hose with a rope. Additionally, there is a retaining ring that may require a special tool or a self-made tool to loosen. It is also important to ensure the fuel level is not too high before starting the procedure.

Removing the rear passenger seat

To remove the rear passenger seat of a 2001 Volvo S60, follow these steps:

First, locate and remove the bolt on each side of the seat back, as well as the electrical connector. Angle the seat up and it will come out. You can refer to a video or a graphic for more clarity on this.

Next, remove the seat base if you haven't already.

Now, remove the cover plate and the two fuel lines. You will see a retaining ring that needs to be loosened. This can be done with a special tool, or you can make your own tool by using two large screwdrivers with the tips set against opposing lugs in an X pattern. This will help offset the expansion force against tapping a single lug. Use the leverage of one screwdriver against the other, and it should come loose.

Once the retaining ring is loose, carefully remove the seat towards the passenger side of the car. Be cautious not to break any tabs or damage any wiring.

Locating the access panel

To locate the access panel for changing the fuel pump in a 2001 Volvo S60, follow these steps:

Begin by locating the rear passenger seat. Underneath this seat, you should see an access panel which will need to be removed. There may also be a retaining ring present that will need to be loosened before you can access the fuel pump. This can be done by using two large screwdrivers with tips set against opposing lugs in an X pattern. Apply pressure and turn counter-clockwise to loosen the retaining ring.

Next, you will need to remove the passenger-side rear seat back. To do this, reach in and hit the release tabs on the side panel. Then, slide the panel up to remove it. Alternatively, pull the top straight towards you and then slide it up.

Once the side panel is removed, you will see a 14mm screw where the seat swivels to fold down. Remove this screw and unplug the plug before sliding the seat towards the passenger side and removing it completely.

With the seat out of the way, you should now have better access to the fuel pump and can proceed with the next steps of the replacement process.

Removing the retaining ring

To remove the retaining ring, you will first need to remove the passenger-side rear seat back. Remove the side panel by reaching in and hitting the release tabs. Then, slide it up to remove it, or pull the top straight towards you and then slide it up.

After removing the side panel, you will see a 14mm screw where the seat swivels to fold down. Unplug the plug and remove the screw. Then, slide the seat towards the passenger side and remove it.

Next, you will need to remove the driver-side sending unit. You will see a hose and some wires attached to the bottom of the sending unit. Unhook them, and tie a small but long rope to the hose with a loop. Undo the passenger-side sending unit, and carefully pull the sending unit out, watching the rope from the other side. Tie the other end of the rope to the door latch on the body to prevent the rope from falling into the tank.

Now, you can focus on removing the retaining ring. It is recommended to use a special tool designed for this purpose. If you don't have access to this tool, you can try using two large screwdrivers with the tips set against opposing lugs in an X pattern. Apply pressure using the leverage of one screwdriver against the other to loosen the ring. Even if you break a couple of lugs, you should still be able to remove the ring. Remember that you will need to loosen the other retaining ring as well, as they are connected.

Disconnecting the fuel lines

First, locate the fuel lines. They are usually found near the fuel filter and the pump. Before you begin, it is important to take necessary safety precautions. Wear protective gear, such as gloves and eye protection, and ensure proper ventilation in the work area to avoid inhaling fumes. It is also recommended to have a fire extinguisher nearby as a safety precaution.

Now, let's begin the process:

• Secure the vehicle on a level surface and engage the parking brake.
• Relieve the fuel system pressure and disconnect the negative battery cable.
• Identify the fuel lines connected to the pump and the fuel filter.
• Place a suitable container under the fuel lines to catch any spilled fuel.
• Using the appropriate tools, carefully loosen the fittings or clamps that secure the fuel lines. Be cautious to avoid damaging the lines or nearby components.
• Once the fittings are loose, gently pull the fuel lines away from the pump and filter. You may need to wiggle the lines gently to detach them completely.
• After disconnecting the lines, plug or cap the open ends of the lines to prevent fuel leakage and debris from entering.
• Place the detached fuel lines in a safe location away from direct heat or sparks.

Remember to work carefully and slowly to avoid any damage to the fuel lines or surrounding components. It is also important to properly dispose of any spilled fuel and contaminated materials according to local regulations.

By following these steps, you will be able to successfully disconnect the fuel lines from your 2001 Volvo S60, making it ready for the next steps in changing the fuel pump.

Replacing the fuel pump

Step 1: Prepare the Car

Before you begin, ensure your car is on level ground and engage the parking brake. Then, disconnect the negative battery terminal and remove the rear passenger seat. You can do this by reaching in and hitting the release tabs on the side panel, then sliding it up and out.

Step 2: Remove the Fuel Lines

Now, you need to remove the fuel lines. First, remove the 14mm screw where the seat swivels to fold down. Next, unplug the plug and move the seat towards the passenger side to remove it. Then, carefully unhook the hose and wires attached to the bottom of the driver's side sending unit. Tie a small piece of string to the hose, and then undo the passenger side sending unit.

Step 3: Remove the Fuel Pump

Carefully pull out the sending unit, watching the rope so that it doesn't end up in the tank. Once it's out, untie the rope and tie it to the new unit, pulling it back through and reinstalling everything. Be sure to use a tool to loosen the retaining ring, and remember to loosen the other side as well.

Step 4: Reinstall the Fuel Lines and Seat

Now, carefully reinstall the fuel lines, ensuring that all connections are secure. Then, slide the rear passenger seat back into place, ensuring it's secure. Finally, reconnect the negative battery terminal.

Tips

• It is recommended to have less than a half tank of fuel when beginning this process.
• Be sure to wear gloves and do this job in a well-ventilated area.
• Be careful not to pinch any wires when reinstalling the sending unit.
• If you're having trouble with the retaining ring, try using two large screwdrivers with the tips set against opposing lugs in an X pattern. This will help offset the expansion force.
• If you're unsure about any part of this process, it's best to consult a professional mechanic.

Parts

• New fuel pump
• String or rope
• Gloves

Frequently asked questions