Replacing The Fuel Pump In A 2007 Volvo S60

Changing the fuel pump in a 2007 Volvo S60 can be a challenging task. It is important to note that this process may vary depending on the specific model and configuration of your vehicle. It is recommended that you refer to your owner's manual or seek advice from a qualified mechanic before attempting any repairs or maintenance. However, here is a step-by-step guide to help you get started:

1. Park your car on a level surface and engage the parking brake.

2. Disconnect the negative battery terminal to prevent any accidental electrical shorts.

3. Locate the fuel pump access panel, which is usually under the rear passenger seat.

4. Remove the rear seat and any necessary trim panels or covers to access the fuel pump module.

5. Disconnect the electrical connectors and fuel lines from the fuel pump module.

6. Carefully remove the fuel pump module, taking note of its orientation and any retaining clips or screws.

7. Obtain a suitable replacement fuel pump and install it in the reverse order, ensuring all connections are secure.

8. Reinstall the rear seat and trim panels, and reconnect the negative battery terminal.

9. Start the engine and check for any fuel leaks or unusual noises.

It is important to exercise caution when working with fuel systems to avoid any safety hazards. Always refer to the vehicle's repair manual for detailed instructions and safety precautions specific to your car.

Removing the rear seats

To remove the rear seats of a 2007 Volvo S60, you will need to first move the front seats all the way forward. Then, locate and remove the bolts and airbag connectors that are holding the rear seats in place. There may also be a metal rod that connects the larger and smaller seats, so be sure to disconnect this as well. Once you have removed all the attachments, you can carefully lift and remove the rear seats from the vehicle.

• Move the front seats: Slide the front seats of your Volvo S60 all the way forward to make room for you to work and to access the rear seats.
• Remove the lower cushions: Flip the lower cushions of the rear seats forward and carefully pry the red plastic trim to remove them.
• Remove the side bolsters: The side bolsters of the seats are usually held in place with some force, so you will need to pull them out with some effort.
• Disconnect the metal rod: If your Volvo has a metal rod connecting the larger and smaller seats, make sure to disconnect this as well.
• Remove the rear cushions: The rear cushions are typically bolted in place and may also have airbag connectors. Remove the bolts and disconnect the connectors before lifting the cushions out.
• Lift and remove the seats: Once all the attachments have been removed, carefully lift and remove the rear seats from the vehicle.

It is important to note that the process may vary slightly depending on the body style of your Volvo S60 (sedan or wagon). Additionally, always refer to a trusted mechanic or a Volvo-specific forum for more detailed instructions and guidance.

Disconnecting the battery

Step 1: Park Your Car

Find a suitable workspace for your car, somewhere you are happy to leave it for a few days if needed. Make sure you have easy access to the interior of the car through both rear doors and the hatch.

Step 2: Move the Front Seats

With the key in the ignition, slide the front seats all the way forward to make more room for the next steps.

Step 3: Disconnect the Negative Battery Terminal

Using a 10mm wrench, disconnect the negative battery terminal. Be sure to tuck it away safely so it cannot reconnect.

Step 4: Remove Forward-Most Cargo Area Flooring (Wagon)

If you have a wagon model, remove the forward-most cargo area flooring to access the battery and other components.

Step 5: Remove Rear Seats

To create more space and access the fuel pump, you will need to remove the rear seats completely. This process may vary depending on your specific model, but generally, you will need to flip the lower cushions forward, carefully pry the red plastic to remove them, and then remove the side bolsters by pulling them out with some force. For the rear cushions, remember to disconnect the airbag connectors and remove the bolts.

By following these steps, you will have safely disconnected the battery in your 2007 Volvo S60, ready to proceed with the fuel pump replacement. Remember to work carefully and wear appropriate protective gear when handling car batteries and fuel systems.

Locating the fuel pump access

To locate the fuel pump access on a 2007 Volvo S60, you will need to first run the car as close to an empty tank as possible. Park the car in a well-ventilated area and disconnect the negative battery terminal with a 10mm wrench.

Next, you will need to remove the front and rear seats to access the fuel pump. For the front seats, simply slide them all the way forward. As for the rear seats, the process may vary depending on the model of your Volvo S60. In some models, you may need to flip the lower cushions forward and carefully pry the red plastic to remove them. The side bolsters can be pulled out with some force. For the rear cushions, remove any bolts and airbag connectors before sliding the metal rod out of the smaller seat.

Once the seats are removed, locate and remove the foam insulation cover to expose the metal hatch covers. These are secured by four 10mm nuts each. Remove these nuts to access the fuel pump underneath.

It is important to note that you should take precautions when working with fuel systems to avoid any safety hazards. Always wear safety glasses and discharge any static electricity by touching the outside of the car multiple times as you enter and exit the vehicle.

Releasing the fuel lines

Before starting, ensure you have the necessary tools and safety equipment, including fuel-resistant gloves, safety glasses, and a fire extinguisher. It is also recommended to have an assistant to help with some steps. Work in a well-ventilated area and disconnect the negative battery terminal before beginning.

• Remove the rear seats and any necessary trim or insulation to access the fuel tank and pump assembly.
• Locate the fuel lines on the driver and passenger sides of the fuel tank.
• Place rags around the fuel lines to catch any spilled fuel.
• Gently pull up on the sending unit on the driver's side. Use a flashlight to locate the yellow suction unit at the bottom.
• Depress the tab to release the yellow suction unit, then unplug the small wiring connector. Allow these parts to rest in the tank where you can still see them.
• Use a transfer pump and gas can to drain the fuel from the driver's side of the tank as much as possible.
• Connect a wire or snake to the loop of the hose you disconnected from the sending unit. Ensure it is smooth and secure.
• On the passenger side, gently pull out the fuel pump assembly, also known as the cup, a little but do not remove it yet. Use the transfer pump to empty the cup as much as possible.
• Locate the small metal float rod on the outside of the bucket attached to a plastic pivoting piece. You can pop this out with a screwdriver, letting it fall into the tank, or leave it attached.
• Pull the pump bucket out until you feel resistance. Use a flashlight to find the float and ensure it is on the passenger side of the bucket before continuing.
• Angle the bucket carefully to avoid damaging the float or yellow connector and remove it completely. Have a bowl ready to catch any remaining fuel.
• With the bucket removed, have your assistant gently push the hose from the driver's side while you guide the hose and bucket out. Take your time and don't force it to avoid kinking the line.
• Once the sending hose is visible on the driver's side, carefully angle and insert the new fuel pump assembly, ensuring the float is correctly positioned.

Remember to take your time and work carefully when releasing and reconnecting the fuel lines to avoid any damage or leaks. Always refer to a trusted repair manual or seek assistance from a qualified mechanic if you are unsure about any steps.

Removing the fuel pump assembly

To remove the fuel pump assembly from a 2007 Volvo S60, you will first need to disconnect the negative battery terminal and remove the rear seats. You will then need to remove the metal hatch covers and release the fuel pressure. Protect the top of the fuel pump assembly with rags and disconnect the fuel lines and wiring harness.

Next, you will need to remove the retaining ring using a special fuel pump removal tool. Once the ring has been removed, you can pull out the sending unit and disconnect the small wiring connector. Be careful not to bend the float. Drain the fuel from the tank and use a snake to connect to the hose.

With the help of an assistant, gently pull the hose from the sending unit while guiding the hose and bucket out. Be careful not to force it and use a flashlight to avoid damaging any components. Once the assembly is out, clean the area thoroughly, including the tank threads and O-rings.

If you are replacing the fuel pump, skip this next part. If you are upgrading, you will need to dissect the old fuel pump assembly and mark the connections with paint markers to ensure proper reassembly. Dry all the gas from the old assembly and place it on a clean, well-lit table. Remove all wiring connectors and pop off the lid. Remove the float sensor and black plastic tabs, then lift out the pump assemblies. Slice the main pump hose connections and carefully remove the pump from the black filter/holder.

Now you are ready to reassemble the new pump assembly. Start by marking each connection with paint markers to ensure proper plug alignment. Disassemble the new pump assembly and cut the connector line from the main pump to the "top hat." Put on your work gloves, apply silicon lubricant to the connection, and heat up the new flex fuel line. Once the line is glossy, push it onto the connection, making sure it goes all the way over the barbs. Allow it to cool and secure it with a hose clamp.

Mock up the proper position of the "top hat" and pump, marking the correct hose placement with a paint marker. Remove everything from the mock-up and work only with the pump and "top hat." Heat the flex hose and push it onto the pump connection, securing it with a hose clamp. Reassemble the entire assembly, twisting the "top hat" to create a nice loop to your pump. Ensure all connections are solid and the black plastic tabs are snapped into the white bucket.

Now you are ready to reinstall the fuel pump assembly. Check again to make sure the tank and O-rings are clean. Holding the assembly above the tank, visualize how you will rotate it as you feed it through. Thread the snake from the driver's side to the passenger side and attach it to the hose. With your helper pulling from the driver's side, gently guide the hoses through. Be careful not to force it and use a flashlight to avoid damaging the float or connector.

Once the sending hose is visible on the driver's side, angle the bucket into place, using a flashlight to avoid damaging any components. Push the bucket partially into place, ensuring the float is on the passenger side of the bucket before pushing it all the way in. Secure the main pump bucket with the special ring.

Install the sending unit/float, facing the arrow toward the rear of the vehicle. Put the float in first, then attach the yellow suction disc to the proper channel. Plug in the electrical connector and push the assembly down, securing it with the special ring. Tighten both rings while holding each unit to stay with the arrow pointing backward.

You have now successfully removed and replaced/upgraded the fuel pump assembly in your 2007 Volvo S60!

Frequently asked questions