Replacing The Fuel Pump In A 2002 Volvo V70 Xc

Replacing the fuel pump in a 2002 Volvo V70 XC is a complex task that requires careful preparation and execution. Online forums provide detailed instructions and tips for completing this process successfully. The fuel pump is located inside the fuel tank, and accessing it involves removing rear seats, insulation, and metal hatch covers. It is crucial to disconnect the negative battery terminal and discharge static multiple times to prevent sparks. Cleaning the tank and its surroundings is essential to avoid debris entering the tank, which can cause clogging. Special tools, such as a fuel pump removal tool and an electricians' snake, are required to remove and reinstall the fuel pump assembly. Upgrading the fuel pump involves additional steps, including marking connections and disassembling the new pump assembly for practice. Safety precautions, such as wearing protective gear and having a fire extinguisher nearby, are vital when working with flammable fuel.

Removing the rear seats and interior carpeting to access the fuel pump

To access the fuel pump, you will first need to remove the rear seats and interior carpeting of your 2002 Volvo V70 XC. Here is a step-by-step guide on how to do this:

Removing the Rear Seats:

• Start by locating the small fabric pull in front of the left-side seat cushion. Pull this up to release the seat cushion latch.
• Fold the seat cushion forward to access the release levers for the seat cushion bracket.
• Press the release levers to unlock the seat cushion bracket.
• Remove the seat cushion from the vehicle.
• To remove the rear backrest, start by removing the side cushion. Pull it out towards the front and then up to remove it.
• Remove the 13mm seat belt fastener.
• Locate the locking clip on the side of the seat using a flathead screwdriver. Lever the locking clip up until it stops.
• Place a block of wood or a large rubber wheel chock on the seat cushion area and another block of wood under the seat back. Use a pry bar to lever the seat upward. This may require some force, so be careful not to slip and damage the vehicle.
• Once the seat back is detached, the mounting wedge will move up and away from the body. When reinstalling, align the wedge and pivot with the slot in the body, then tap it back down.
• Angle the seat back towards the door and remove it by pulling it straight off the pivot.

Removing the Interior Carpeting:

• Lift the soundproofing carpeting out of the way to expose the two round black covers on each side of the floor.
• Remove the four nuts from each cover.

Now that you have removed the rear seats and interior carpeting, you should be able to access the fuel pump on the right-hand side of the vehicle. Remember to disconnect the battery and take the necessary safety precautions before proceeding with the fuel pump replacement.

Disconnecting the fuel lines and electrical connectors from the fuel pump

Preparation:

• Ensure the fuel tank is at a minimum level. It is recommended to run the car as close to an empty tank as possible before beginning the replacement process.
• Disconnect the negative battery terminal and set it aside, ensuring it cannot reconnect.
• Remove the rear seats and the forward-most cargo area flooring to access the fuel pump area.
• Clean and vacuum the rear area, including the top deck and spaces between seatbelts, to prevent debris from falling into the tank during the replacement process.

Disconnecting Fuel Lines and Electrical Connectors:

• Remove the metal hatch covers on both the driver and passenger sides, unscrewing the four 10mm nuts on each cover.
• Protect the top of the fuel pump assembly with rags.
• Gently press the sides of the fuel lines to release the pressure and catch any fuel in the rags.
• Disconnect the wiring harness from the fuel pump assembly by pressing the tab and pulling the harness upward.
• Carefully tuck the fuel line connectors out of the way by pushing them between the metal body and the fuel tank.
• On the driver's side, pull up gently on the sending unit to access the yellow suction unit at the bottom.
• Depress the tab on the yellow suction unit to release it, and then unplug the small wiring connector, allowing it to drop into the tank.
• Remove the sending unit by carefully pulling it out of the tank.
• Attach a string or wire to the attachments on the sending unit, ensuring it is long enough to reach the other side of the tank.
• On the passenger side, locate the electrical connector for the fuel pump and disconnect it by pressing the tab and pulling it out.
• Gently pull out the fuel pump cup/bucket, being cautious not to force it and damage the float or other components.
• Once the bucket is out, carefully guide the hose from the sending unit (driver's side) through the tank to the passenger side.

It is crucial to work slowly and carefully during this process to avoid any damage to the fuel lines, electrical connectors, or other components. Take your time and ensure all connections are securely made and components are handled with care.

Removing the fuel pump locking ring and extracting the old pump

To remove the fuel pump locking ring and extract the old pump, you will need to follow these steps:

• Disconnect the negative battery terminal and tuck it away so it cannot reconnect.
• Remove the rear seats.
• Remove the foam insulation cover.
• Clean the area, removing any debris.
• Remove the metal hatch covers.
• Depress the pin on the Schraeder valve to release fuel pressure.
• Protect the top of the fuel pump assembly with rags and press both sides of the fuel lines to release them and catch fuel in the rags.
• Unplug the wiring harness to the pump assembly.
• Clean the area again, ensuring that there is no debris that could fall into the tank.
• Using the special fuel pump removal tool and a ratchet, remove both rings.
• Pull up gently on the sending unit and locate the yellow suction unit at the bottom. Depress the tab to release it.
• Unplug the small wiring connector and let it drop into the tank.
• Remove the sending unit by carefully pulling it out of the tank.
• Drain the side of the tank with a transfer pump and gas can.
• Use a snake to carefully connect it to the loop of the hose you disconnected from the sending unit.
• Pull the cup out gently from the passenger side and drain the cup with a transfer pump.
• Locate the small metal float rod on the outside of the bucket and pop it out with a screwdriver.
• Pull the pump bucket out, tilting the bucket to avoid catching the float and yellow hose attachment.
• With the old pump removed, thoroughly clean the inside and outside of the tank to 100% perfection.
• Take your clean O-rings for the fuel access doors and apply a small amount of synthetic grease until lubricated. Apply a tiny amount to the threads of the special rings.

Installing the new fuel pump and securing it with the locking ring

Now that you have removed the old fuel pump, it is time to install the new one.

First, put the new O-ring seal on the new pump. Then, put the new pump into the tank. When screwing on the locking ring, clean the tank threads and apply a little lube to make it easier to screw on. Screw down the locking ring and install the big hose clamp.

Next, re-attach the fuel lines. These will need some pressure to lock them in place. Pull on them to ensure they are secure.

Now, cut the wires on the new pump, leaving about four inches attached to the new pump. Put a piece of heat shrink tubing over the wires so you can later seal it over the connectors for a completely dry and worry-free installation. Then, strip and crimp all the wires. The two white wires are for the fuel gauge, and it should not matter which you connect to which. The red and black wires are obviously hooked to the red and black. Heat the connectors to shrink and heat again after putting on a piece of heat shrink tubing first. Tuck the wires away.

You can put some metal tape along the top edge. As you may not be able to fit an aluminium strip there, you can put something in place to catch the sealant you will apply later. It was bent back in the photo but goes all the way across the top.

Finally, use self-tapping sheet metal screws to close the cut and seal it with black silicone. Let the silicone dry for a day, which will add some structural integrity. Cover the cut with metal tape and put everything back together.

Reattaching the fuel lines, electrical connectors, and interior components

Once you have successfully removed the fuel pump, you can begin the process of reattaching the fuel lines, electrical connectors, and interior components. Here is a step-by-step guide to help you through the process:

Reattaching the Fuel Lines:

• Before reattaching the fuel lines, ensure that the new pump is securely installed and the locking ring is tightened.
• Clean the fuel line connections on both the pump and the vehicle's fuel system.
• Carefully connect the fuel lines to the new pump, ensuring that the connections are secure and there are no leaks.

Reattaching the Electrical Connectors:

• Locate the electrical connector for the fuel pump. It should be near the pump assembly.
• Ensure that the connector is properly aligned and plugged into the fuel pump.

Reinstalling the Interior Components:

• Reinstall the rear seats and cargo area flooring that you removed earlier.
• Make sure to reconnect any electrical components, such as airbag connectors, that were disconnected during the removal process.
• Replace the insulation and carpeting in the cargo area, ensuring that everything is securely fastened and in its original position.

Final Checks:

• Before closing the fuel pump access panel, double-check all your connections, including the fuel lines and electrical connectors.
• Reconnect the negative battery terminal.
• Refill the fuel tank.
• Start the car and check for any leaks or unusual noises.
• Test drive the vehicle to ensure that the new fuel pump is functioning properly.

Remember to take your time and work carefully. Fuel system repairs can be delicate, and it's important to avoid any leaks or damage to the electrical components. If you're unsure about any steps or encounter any issues, don't hesitate to seek assistance from a qualified mechanic.

Frequently asked questions