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How to Change a Fuel Pump in a 1995 Volvo 960

The Volvo 900 series is a range of mid-size cars manufactured by Volvo Cars. The Volvo 960 was a luxury car produced from 1990 to 1997, with the 1995 model representing major changes in design. It had a six-cylinder 2.9-liter engine with electronic fuel injection, requiring a high-pressure fuel pump. The fuel pump in the 1995 Volvo 960 is accessible from the floor of the rear seat.

Instructions

1

Disconnect the cable from the negative battery terminal with a socket wrench. Connect adapter 999-5484 to fuel drainage unit 981-2270. Remove the cap from the pressure relief valve on the fuel rail. Close the adapter valve, and connect it to the pressure relief valve. Turn the drainage unit on, and open the adapter valve. Raise the vehicle on jack stands, and remove the valve cap on the fuel filter. Connect hose 999-5480 to the valve on the fuel filter, and drain fuel from the fuel system for about two minutes. Disconnect hose 999-5480 from the fuel filter valve, and replace the valve cap. Lower the vehicle. Disconnect the adapter from the pressure relief valve, and replace the cap on the pressure relief valve.

2

Move the rear seat forward. Fold back the carpet over the right wheel well panel, and remove the panel to expose the fuel pump. Disconnect the electrical connections for the fuel pump, and loosen the quick-connect fittings for the fuel lines to the fuel pump. Turn the retaining nut on the fuel pump counterclockwise with tool 999-5485, and carefully remove the fuel pump. Discard the rubber seal under the fuel pump.

3

Install a new rubber seal, and apply a thin layer of petroleum jelly to the seal. Install the pump so the heater connection faces to the right of the vehicle. Attach the retaining nut to the fuel pump with tool 999-5484 and tighten it to 30 foot-pounds.

4

Apply a thin layer of petroleum jelly to the fuel lines, and connect them to the fuel pump. Ensure that you properly seat the quick-connect fittings onto the pump. Attach the electrical connector to the fuel pump.

5

Replace the panels and carpeting in the rear of the vehicle, and move the rear seat back to its upright position. Connect the cable to the negative battery terminal with a socket wrench. Start the engine and check for fuel leaks.