Replacing Fuel Pump Relay In Volvo 940: Step-By-Step Guide

If you're having trouble locating the fuel pump relay in your Volvo 940, you're not alone. The relay is typically found behind the ashtray in the center console, but some owners have reported difficulty accessing it. In some models, there may be a second relay under the hood, and in others, the relay may have been relocated altogether.

Before attempting any repairs, it's important to consult a qualified mechanic or a trusted Volvo forum for specific instructions pertaining to your car's make and model.

The fuel pump relay is located behind the ashtray in the centre console

To access the fuel pump relay, you will first need to locate the ashtray in the centre console of your Volvo 940. Remove the ashtray and set it aside.

Behind the ashtray, you will find the fuse tray, which holds the fuel pump relay. To remove the fuse tray, you will need to release the two clips holding it in place. Gently push aside the clips and loosen the fuse tray.

At this point, you should be able to access the fuel pump relay. It will be located on the fuse tray, either in the far left second row or the front row, second from the left. The relay is small and black or white/green in colour.

Once you have located the fuel pump relay, you can proceed to replace it with a new one. Simply pull out the old relay, and plug in the new one. Ensure that it is securely connected before putting back the fuse tray and ashtray.

There are two fuel pump relays in the Volvo 940

To access the relay behind the ashtray, first remove the ashtray itself. You may also need to remove the cigarette lighter and the surrounding trim. This will expose a screw that secures the cubby to the console. With the cubby removed, you will have easy access to the relays.

The relay under the hood is easy to identify as it is the only relay with four wires. It is also larger than the other relay.

Both relays can be removed by simply pulling them out. When replacing them, ensure that you plug the new relay into the correct slot.

The relay just pulls out and a new one plugs straight in

To replace the fuel pump relay in a Volvo 940, first, locate the relay. It is behind the ashtray in the centre console.

To access the relay, you will need to remove the ashtray. There are two clips holding the fuse tray in place; push these aside and remove the ashtray. You may also need to remove the cigarette lighter tray above the fuse tray to gain access. There are two screws on the left-hand side of the cubbyhole that secures it to the console.

Once you have removed the necessary components to access the relay, simply pull out the old relay. It should come out easily, but if it is stuck, you can use a tool such as a screwdriver or spark plug puller to help remove it. Be careful not to damage the surrounding components when removing the old relay.

Now, take the new fuel pump relay and plug it into the vacant slot. Ensure that it is securely in place.

Finally, reassemble the components you removed to access the relay. Screw the cubbyhole back into place and push the fuse tray back in, ensuring that the clips hold it securely. Put the ashtray back, and you're done!

The fuel filter is located under the car, beneath the rear seat

To change the fuel pump relay in your Volvo 940, you'll first need to locate the fuel filter, which is situated under the car, beneath the rear seat. Here's a step-by-step guide to help you through the process:

Before beginning any work, it is important to ensure your safety. Make sure you wear appropriate protective gear, such as gloves and eye protection, and that you are working in a well-ventilated area.

Step 1: Prepare the Car

Turn off the ignition and remove the fuel filler cap to release pressure from the fuel system. This is an important safety precaution as you will be working with flammable fuel.

Step 2: Access the Fuel Filter

Position yourself under the rear seat of the car, where you will find the fuel filter/pump carrier assembly. This assembly holds the fuel filter in place.

Step 3: Loosen the Fuel Filter Assembly

Remove all but one of the bolts from the fuel filter/pump carrier assembly. Loosen the last bolt but do not remove it completely. This will allow the carrier to hang from the vehicle, providing access to the fuel filter.

Step 4: Prepare for Fuel Release

Have a fuel-resistant container ready to catch any excess fuel that may spill during the process. Fuel lines are under pressure, and fuel may spray from loose connections until the pressure is relieved. Use a shop towel to cover the outlet connection of the fuel filter to protect your face from fuel spray.

Step 5: Relieve Fuel Pressure

Loosen the connection at the outlet of the fuel filter to relieve the remaining fuel pressure. Some fuel will run out of the hose and filter, so be prepared to catch it with your container.

Step 6: Remove the Fuel Filter

Remove the banjo bolt from the inlet side of the fuel filter. Then, remove the fuel filter mounting clamp and the fuel filter itself. Be careful not to spill any remaining fuel during this process.

Step 7: Install the New Fuel Filter

Install the mounting clamp onto the fuel filter/pump carrier assembly and start tightening the bolt, but do not fully tighten it yet. Slide the new fuel filter into the mounting clamp, ensuring that it is installed in the direction of fuel flow. Check the markings on the filter to confirm the correct orientation.

Step 8: Secure the Fuel Filter

Tighten the filter mounting clamp to secure the new fuel filter in place. Reinstall both fuel filter hose connections, using new gaskets for a tight seal.

Step 9: Reassemble and Check for Leaks

Remount the fuel filter/pump carrier assembly and reinstall the fuel filler cap. Start the engine and carefully check for any leaks at the filter connections.

By following these steps, you can safely replace the fuel filter on your Volvo 940. Remember to work cautiously when handling fuel and always dispose of it properly. If you are unsure about any part of the process, it is best to consult a qualified mechanic.

The fuel pump may be located under the driver's seat

The first step is to pull the fuel pump fuse while the engine is running, causing the engine to stop with no fuel pressure left in the line. Then, shut off the engine and remove the key from the ignition.

Next, spray the fuel filter fittings with penetrating oil. The filter and pump sit in a subframe or cradle under the driver's side of the car, mid-ship, held up by three 10mm bolts. The pump is held in place with a cushioned band clamp and one 10mm bolt, which can only be accessed by lowering the tray.

Now, loosen the carriage that holds the filter by removing only the outside nut that holds it up, then bend the carriage down to work on the filter. Unplug the main fuel pump electrical connections, disconnect the fuel tank line (don't forget to plug this line), and disconnect the line to the engine.

To remove the filter, you will need to loosen the clamp around the middle. When installing the new filter, replace the fuel filter and banjo gaskets, and use grease as an anti-seize on the threads and washer flats of the fittings, but don't get any grease in the fuel intakes. The new filter will come with four copper crush washers, two for each compression fitting.

Finally, cinch the clamp, bend the cradle back up, and tighten the bolts. Check for leaks when you are done and the engine is running.

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