I hoped to be able to report a successful conclusion to the fuel pump replacement, but it remains a work in process.

Da Dreaded Rubber Ring (from Kuba's post) would not allow the sender to seat. I was literally 1/4" away from having it back in, but the sender could not be budged in the ring. The WD 40 he recommended as a lubricant does not seem very slick in the 25 degree temps we've been having here in Chicago. The garage can be heated to about 50 with a sealed oil electric radiator, but I'm also opening the garage door half way to vent the fumes from the open tank.

Tonight I pulled the sender back out far enough to remove the ring and brought the seal inside to let it come back to room temperature.

I noticed on the old seal that there is a band of white residue around the ring close to the lip. I'm guessing that this is the remainder of white lithium grease that was used to install the pump before. I'm thinking about applying some lithium grease to the sender and seal. Basically the same way it was applied to the old seal.

Anyone have an opinion about getting a little lithium grease into the fuel?

It seemed to be the only lubricant that would allow the front oil seals to seat correctly with my jury rigged seal press tool.

Volvo part numbers and prices for the parts are as follows:

Fuel Pump 9445444-4 $208.00
Sealing Ring 1367623-4 $ 10.19

Car is a 1995 940 8 valve.

Roger

"I was literally 1/4" away from having it back in, but the sender could not be budged in the ring."

That sounds like you put the seal (ring?) on the tank and are now trying to insert the sender. I'd try putting the seal on the (lubed) sender first, then lube the outside of the seal with dish detergent and see if the seal-sender combo will go home.

I honestly don't recall which way I did mine—nor does Art's pictorial mention it, but at this point I think this approach is worth a shot.

Thanks for the part # and price info.For future refrence, OE parts are discounted a good 20% at the Tasca Auto Group in Seekonk, MA, with low-rate (commercial) UPS rates. See http://www.getvolvoparts.com/, where I just got the following:


Multi-Part Search

Part Number Search Results : OEM Catalog
Item Number MSRP Core Price Price
94454444 $205.19 $0.00 $151.02

FUEL PUMP
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Bruce Young
'93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

Bruce,
I tried it with the ring on the sender first and the outside ring was hanging up on the edge of the tank. I then backed out and tried putting the seal in the tank with the seals outside ring just past the edge of the tank. The WD40 didn't seem very slick in the cold and the sender just went in so far and stopped. Couldn't budge it. I'm going to try again tonight.

I checked out the place you mentioned before I bought the pump. Their web price was (and is) $184 on a pump with no part number. I was concerned about getting the wrong pump since IPD told me they had no documentation on a single in-tank pump for a 940. I've normally bought mail order from IPD. I will definitely save the link for future reference.

Thanks
Roger

Roger,
When you say:

"I checked out the place you mentioned before I bought the pump. Their web price was (and is) $184 on a pump with no part number."

Do you mean "getvolvoparts.com (Tasca)? If so, I'll quit recommending them. That price quote above came from their website this morning.

WD40 is a great Water Dispersant but I don't think much of it as a lubricant. Seems like that seal, meant for a (fuel) environment, would handle most any common grease. But I also think dish detergent works well too.

Wish I could say which way is best—seal on tank or seal on sender. Looking at Art's pics again, his seal was still on the tank when the sender came out, as shown below:



A later pic (below) shows the seal on the sender prior to installing. But I don't know if that's how it actually went in. In any case, I think a good, slippery lube is the answer.



--
Bruce Young
'93 940-NA (current), 240s (one V8), 140s, 122s, since '63.

Bruce,

I see what happened. If you go in with a part number the price is $151. If you go the Year, Make, Model, Component route it takes you to the $184.00 price.
Wonder why they would have it set up that way?

A little lithium grease on a Que-Tip around the edges of sender and seal did the trick. I placed the ring part way into the tank then pushed in the sender. Nice tight fit, but everything moved smoothly. After I got it in, the level was a little off. I was able to back the sender out a bit, rotate it, reseat it and tighten it down with the nut. I am going to replace the rubber fuel hose coming from the sender then I should be ready for a pressure test tomorrow.

Roger