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I have an 1995 8v 945 with a failing fuel pump (I think). Over the holiday I'm near a junkyard with the inventory posted below. I can't tell from eeuroparts which years of the 240/740/940 share the same fuel pump. If you know which models would have a compatible (in tank) fuel pump, I'd be grateful!
regards!
ID Make Year Model Desc. Date Received
UV4220 Volvo 1988 240 maroon sw 09/28/2011
UV4280 Volvo 1990 240 blue 10/05/2011
UV4658 Volvo 1989 240 blue 11/04/2011
UV4797 Volvo 1989 740 blue sw 11/11/2011
UV4981 Volvo 1987 740 black sw 11/28/2011
UV4485 Volvo 1995 850 blue 10/19/2011
UV4615 Volvo 1993 850 green 10/31/2011
UV4594 Volvo 1993 850 green 10/31/2011
UV5079 Volvo 1991 940 black 12/02/2011
UV4917 Volvo 1996 960 black 11/22/2011
UV5131 Volvo 2000 S40 white 12/08/2011
UV4599 Volvo 2000 V40 blue 11/02/2011
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Dear beefstew,
Hope you're well. The '95 940, non-turbo, has a single in-tank pump (Volvo Part #9438001, replaced by #9445444).
Prior to 1992, the Bosch-supplied, two-pump fuel system was the norm: a small in-tank pre-pump and a main pump externally-mounted on the floor pan, under the driver's seat. As a result, in-tank pumps from pre-1992 models (240s and 740s) cannot be used in a '95 940. These in-tank pumps simply lack the power to move enough fuel.
Fuel pumps from model 850s might have enough power. However, the fuel pump arrangement is so different from that of the 940s, that the pump might not even fit on a 940 car's fuel tank send unit. The same applies to fuel pumps used in any post-2000 car.
For in-tank pumps, pump dimensions matter: there's not a lot of room to spare, when it comes to removing a 940's fuel send unit (with attached pump) from the tank. I do not recall reading a post over the past few years, in which anyone reported using in a 940 or 960, a fuel pump for a 850 or an S/V 40.
Thus, the range of donor cars is limited to 940s and 960s. Even within this narrow range, great care is needed. Few, who post on this Board, seem to have experimented. Rather, they have replaced the single, in-tank pump on a '95 940 with the exact same part.
Because in-tank fuel pumps are not easy to access, few seem to have wanted to experiment with even a factory-fresh pump, not specified for a '95 940. Even less so would one want to experiment with a pump from a donor car, unless the pump's appearance suggested it was nearly new. A nearly-new pump's plastic fittings will be bright white plastic. A "low miles" pump will be a light light ocher or a pale-to-medium brown. Generally, the darker the deposits on the pump, the older it is.
In 1992, the Rex-Regina fuel/ignition management system - with a single, in-tank pump - was introduced for non-turbo engines. Also, in 1993 and 1994, both non-turbo and turbo-equipped cars also were made with the two-pump Bosch fuel delivery/management system. Thus, in 1993 and 1994, Volvo made 940s for sale in North America, that had a single fuel pump (Rex-Regina; with light blue fuel injector caps) or two fuel pumps (Bosch, with bright yellow fuel injector caps).
A pump from a car with Rex-Regina fuel management system might work in a '95 940. I do not recall a post reporting such an experiment. The likely reason: accessing the in-tank pump is time-consuming. Few would want to have to do this twice, i.e., to install a Rex-Regina pump in a '95 Bosch-equipped car, only to find that it didn't work.
In 1995 - the last year the 940 was sold in North America - non-turbo cars had either the single pump Rex-Regina fuel management system, or the single-pump Bosch fuel management system. I infer from the fact that these pumps have different part numbers - (Bosch, non-turbo, #9438001 replaced by #9445444); (Rex-Regina #3507736) - that these pumps do not interchange. The turbo-equipped '95 940s used a fuel pump with #9438756.
Up to and including 1994, 960s used a two-pump set-up, with the main pump externally mounted, just as it is on a '94 or earlier Bosch-equipped 940. Because this externally-mounted pump supplied a six-cylinder engine, 960s require a more powerful main pump, than do 940s with a two-pump fuel delivery system. Until 1994, the 960's in-tank pump (#3507436) was the same as that used on non-turbo 940s.
In 1995, 960s were first equipped with a single, in-tank pump (#9438756). I do not know if this pump would work in a 95 '940. It likely is over-powered for a 940.
In short, the single in-tank pump used in '95 940s seems to be unique. Therefore, I'd only replace it with the identical part.
All this said, there will be an example or two of exceptions to everything above-stated. Because there 940s and 960s (and likely most other fuel-injected engines) have a fuel pressure regulator, the risk of using a non-specified pump is under-power, rather than over-power. If too little fuel is delivered, the engine won't run properly.
Fuel pushed by an over-powered pump won't be needed, and will be returned to the tank. However, excessive pump pressure could damage/destroy the fuel pressure regulator. This part is easy to access, being atop the engine. But it isn't a low-cost item.
Hope this helps.
Yours faithfully,
Spook
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I forgot; some who hotrod their cars and make big HP numbers which a stock pump cannot cope with, use a single Walbro intank pump. Some research may indicate which model etc. They seem to be well made and reliable, and may have a model that will work fine for a stocker.
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Thanks for the informative reply! Given the poor compatability, I'll probably skip what sounds to be a sissyphian repair.
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Dear beefstew,
Hope you're well. You're welcome. The repair is manageable, especially if the car is a wagon (more work room). I simply wanted to be sure You didn't embark on the repair, only to find out that the pump wouldn't fit at all, or would fit, but couldn't deliver the right amount of fuel.
See the FAQs for the proper procedure. It is important to keep in mind that when in its proper place, the fuel send unit's barrel points down to the ground, and is parallel to the fuel tank's back wall (that closest to the trunk/rear hatch). Right in front of the barrel, is a plastic part, a baffle, that limits fuel slosh on turns and sharp stops/accelerations. This baffle keeps the fuel gauge from jumping around.
To remove the fuel send unit, it has to be turned in a clockwise direction, while the barrel's end is brought upwards, so that it points to the front of the car. In so doing, the barrel is moved from pointing to the ground, to pointing forward (towards the engine compartment). Once the barrel has been lifted and turned, the barrel is above the anti-slosh baffle. The fuel send unit can then be removed from the tank.
The fuel tank send unit is accessed with a small panel, in the trunk, just behind the rear seat and in a wagon, under the load space floor, just ahead of the wheel wells.
Hope this helps.
Yours faithfully,
Spook
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Thanks for the replies. Is the pump different, or is it primarily a difference in the mounting/housing?
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Dear beefstew,
Hope you're well. I presume you refer to in-tank pumps. The in-tank pre-pumps are much smaller than the in-tank main pump.
For different in-tank pumps, pump body diameter is not the same. Diameter matters more than does length. These pumps sit in a plastic "cup", attached to the fuel send unit by a springy metal bracket. If the cup is too narrow, the pump won't fit. If the cup is too wise, the pump will not be held firmly in place.
A length of rubber hose (rated for fuel injection pressure) connects the pump with the top of the send unit. This hose can be bought at an auto parts store, so when replacing the pump, it is a good idea to replace the hose, which probably will have hardened with time. Be sure to tighten the clamps, that secure this hose to the pump and to the tube, that protrudes downwards, from the fuel send unti's top cover. Some have posted that the pump-to-sender hose worked loose. A loose hose cuts fuel volume and/or pressure: the engine runs poorly, at best.
Hope this helps.
Yours faithfully,
Spook
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I think only the 1995 960 in tank fuel pump will work. I think the sending unit is probably different.
--
john
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95 is one pump intank model and is not compatible with any earlier models. It apparently is the same as some 960's though; search the parts sites for similar numbers, it may be that one 960 is the right one. Spook knows I think, maybe he'll see this.
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