Replacing Fuel Pump In 2004 Volvo Xc90: Step-By-Step Guide

how to change fuel pump 2004 volvo xc90

Replacing the fuel pump in a 2004 Volvo XC90 can be a challenging task. While it is not extremely difficult, it is time-consuming and requires careful attention to safety precautions. Before beginning the process, it is crucial to disconnect the battery to reduce the risk of fire. Additionally, it is recommended to have as little gas in the car as possible to avoid spilling fuel during the process. The next steps involve removing the rear seats, folding up the carpet and padding, and exposing the fuel pump cover. Special tools, such as a pump retaining ring tool, may be required to loosen and remove the fuel pump retaining ring. It is important to clean the area and disconnect the fuel lines and electrical connections before installing a new fuel pump. Overall, the process can take around 3-4 hours to complete, and it is important to work slowly and methodically to ensure a successful fuel pump replacement in a 2004 Volvo XC90.

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Disconnect the negative lead to the battery

Disconnecting the negative lead to the battery is an important first step when working on any car repairs. This is because the negative battery terminal, also known as the ground strap or cable, is directly connected to the vehicle's engine, body, and chassis.

Before disconnecting the battery, ensure the engine is turned off. Attempting to remove a battery while the engine is on can cause damage to sensitive electronics.

Now, locate the battery. Most vehicles have it under the hood, while some have it in the trunk. Consult your owner's manual to determine the location.

Once you've located the battery, identify the battery terminals. The negative terminal is usually denoted by a "-" symbol and a black battery cable connected to it. The positive terminal, on the other hand, has a "+" symbol and a red cable connected to it.

To disconnect the negative lead, follow these steps:

  • Put on safety gear: Safety glasses and gloves are recommended to protect your eyes and hands. Remove any jewellery to avoid accidental electrical contact.
  • Use the right tools: You will typically need a 10-millimeter open-end wrench to loosen the nut on the negative terminal. Ensure you only use one wrench and that it does not touch the other terminal when working on the battery.
  • Loosen the nut: Use the wrench to loosen the nut on the negative terminal first. It is crucial to start with the negative terminal to avoid any electrical hazards.
  • Remove the cable: After loosening the nut, lift the black negative cable away from the battery post. Ensure that the cable is kept away from the battery and does not touch the positive terminal.
  • Secure the cable: Make sure the negative cable is securely placed away from the battery and cannot accidentally come into contact with the terminals.

By following these steps, you will have successfully disconnected the negative lead to the battery in your 2004 Volvo XC90, ensuring a safer environment for you to proceed with your fuel pump replacement or other repairs.

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Remove back seats

To remove the back seats of a 2004 Volvo XC90, follow these steps:

First, remove the seat bottom. There are four covers on the front of the seat bottoms, and underneath are four 10mm bolts. Take those out. Once those are taken out, the whole seat bottom should be able to lift up and out of the car.

Next, remove the side padding pieces. Pull them outwards towards the front of the car to remove the clip, then lift the piece up.

Now, take your 13mm socket and unbolt the bolt holding the swivelling bracket, and rotate it up.

This is the semi-hard part. There is a black knob with an allen key end to it, that needs to be rotated outwards in order to get the seat backs off of the rail. You can use an allen key or your hands to loosen the knob, enough to where it is separated from the rail. Once you do this, push the seat in towards the centre of the car to get the seat off of the rail, then pull the whole seat upwards, and it should pop out.

At this point, all of the seats are out! There are still a couple of other things you can do. The seat belts are held in by bolts, and the outer seat belt bolts are 13mm, and the bolts that hold in the buckles are 15mm. DO NOT attempt to completely take out the seatbelt, as it will trigger an SRS airbag message, that can only be reset by the dealer or a tuner. Instead, take off the plastic piece that the seat belts come out of (be very gentle, they break easily!) and slowly tuck the belts in to that opening, then put the cover back on.

That's it! There are a few brackets and other things that can be taken out, however, this is the extent of the information I could find.

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Remove carpet and foam inserts

To remove the carpet and foam inserts of your 2004 Volvo XC90, first remove the back seats. There are four 13mm bolts holding each seat in place. The front bolts are easy to access after removing the plastic covers. Simply push down on a single tab and slide the covers forward. To access the rear bolts, remove the floor panel in the cargo space. It is not bolted down, so this should be easy to do. Once all the bolts are removed, the seats will come out easily.

Next, remove the carpet. It should come up easily. There are also two foam inserts that need to be removed. Removing the carpet and foam inserts will reveal the two access panels for the fuel pump and level sensor.

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Remove access panels

To remove the access panels of a 2004 Volvo XC90 to reach the fuel pump, follow these steps:

First, disconnect the negative lead to the battery and let the car sit for a few minutes to avoid any unwanted airbag deployment.

Next, remove the back seats. If your XC90 has a third row of seats, you will need to remove those as well. Note that the middle seat has an electrical connector that needs to be unhooked. Each seat is held on by four 13mm bolts. The front bolts are easy to access after removing the plastic covers. To remove the rear bolts, remove the floor panel in the cargo space.

After removing the seats, the carpet comes up easily. There are also two foam inserts that need to be removed. This will reveal the two access panels for the fuel pump and level sensor.

The access panel on the driver's side (fuel level sensor side) is held on by four 10mm nuts. Remove these nuts and work the access panel off the studs. One of the nuts is located under the seat frame and may be difficult to access. Carefully remove the rubber gasket from the access panel and set it aside. The gasket has one wire going through it, which should be unplugged and removed from the gasket.

The passenger side (fuel pump side) has a lot more connections and hoses to deal with. Remove the electrical connection and gas lines, and move them out of the way.

Once all the connections and hoses have been removed, the access panels can be lifted off, providing access to the fuel pump and level sensor.

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Remove lock rings

To remove the lock rings of the fuel pump of a 2004 Volvo XC90, you will need a special tool. You can either buy one or make one yourself. A screwdriver and hammer will probably not be sufficient.

One option is to buy the Lisle 63000 Fuel Tank Lock Ring Tool on Amazon. This tool has been designed to remove and install the left and right fuel pump retaining nuts (also called lock rings) on all late model Volvos without dropping the fuel tank.

Another option is to make your own tool. One person on the Matthews Volvo Site forum made a tool out of a PVC adapter bought for $3 from Home Depot, cutting slots every 20 degrees with a Dremel.

  • Disconnect the negative lead to the battery and let the car sit for a few minutes to avoid any unwanted airbag deployment.
  • Remove the back seats.
  • Remove the floor panel in the cargo space.
  • Remove the carpet and the two foam inserts underneath.
  • Remove the access panel with a 10mm wrench.
  • Unplug the wire from the rubber gasket and set the gasket aside.
  • Remove the lock ring with your chosen tool.
  • Remove the fuel pump hoses from the level sensor.
  • Remove the level sensor from the tank.
  • Vacuum up any dirt and remove the o-ring.
  • Tie a wire or string to the fuel pump hoses so you can feed the new hoses back through when you install the new pump.

Note: Be very careful not to vacuum up any gas.

Frequently asked questions

If your fuel pump is faulty, your engine may not start or run, or your car may keep stalling. You may also notice a strong fuel smell, or that your car is not running smoothly.

Changing the fuel pump in a 2004 Volvo XC90 is a complex task that requires a lot of steps and specialist tools. It is not recommended for those who are inexperienced with car repairs.

You will need a fuel tank lock ring tool, a vacuum, and a ratchet with a 6" x 1/2" extension. You may also need a tool to disconnect the negative lead to your battery.

You should ensure your fuel tank is as empty as possible before attempting to change your fuel pump.

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