Hi,

Glad to hear it wasn’t a water in the fuel problem.

I have seen the seven series pump arrangement along with the instrument clusters being made in Japan.
The introduction of the 700 made me not like its GM or Chrysler Le Baron looks to begin with.
Despite the seating interiors looked to be more creature friendly and all.
I have learned that if they go to the trouble to hide the interior decor without showing how the cars become more of an expensive looking luxury to Volvo that was an upgrade but not for true blooded 200 series eyes.

I too have wondered why they turned their back on the 240 in-tank fuel arrangement.
At least they kept the topside access available.
Having to drop complete gas tanks on some cars is a major chore.

I’m not sure even if Bosch even makes those feed pumps as there are so many replacements from other brands like Delphi, AC Delco or VDO for many other cars.

I have noticed that the original in tank pumps on the 240s had a ring extrusion on the main body. Those have disappeared.
My tank senders used it in their holders to keep the pump up into the factory accordion hose.
This allowed the pump to float upwards but not down lower than that ring as not to pull on the connectors hose. No clamps were used as I remember.

So with new replacements I have always added a tight a #6 grade nylon wire tie to the body of the pump above the holder after assembly.
It will do the same thing as the extruded ring in function.

I was wondering the sending unit on 700s might that have the pump is held down lower on the overall stack up. It would explain the tight fit vertically.
This is if a connecting hose too long or was straight and stiff. Bingo?

Did you notice if they designed the sender in such a fashion?

Or like you said, improvise!

Phil