For fuel pump and filters - what brands have you had the best luck with - quality, performance and longevity.

Thanks

Rockauto usually has the best prices and does carry the Bosch main pump at the moment, which should be identical to the model they make for Volvo. I've also used the significantly cheaper Hella in-tank pumps and not been disappointed if you find those available, sometimes also sold labelled under another brand until you see the box. Anything FCP sells can be trusted these days and they do stand behind their products as well as provide excellent customer support.

The lifespan of in-tank pumps can be affected if you constantly run around with a low tank fill as it makes them work a hair harder, but most important is the cooling when the pump remains submerged most of the time.

For filters, always go for Bosch to play it safe. Different part numbers can be associated with whether you get the copper crush rings. You can usually reuse the old rings, but might want anneal them first.
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Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now

When I disconnect the connections how much fuel will run out? A lot ? - do I need to crimp hose, or is it prevented from doing so by the in tank pump?

Thanks

Like Randy says, for the main pump a small pan underneath should suffice. Expect to lose a minimum of maybe a cup of fuel. After cracking the connections loose, be prepared to either keep working to do the install or else plug the lines. Best to release fuel system pressure first, either at the Schrader valve on the fuel rail into a small container or by pulling the two pump fuses and trying to start the engine. If you don't have flare wrenches then this an excellent excuse to buy them. I justify such purchases using the money saved on shop labor. A flare wrench on the fuel line fitting with a box wrench as a slightly offset counterhold squeezed together as hard as you can will do the job and minimize damage to the brass fittings. Maybe hit both sides of each fitting with a little PB Blaster and let it soak in a bit. As you start to turn a line fitting, make sure it's let go of the fuel line and not twisting it otherwise you'll be into a much bigger job. Best also to have a selection of narrow plugs and/or plastic caps handy to slow/halt the flow from at least the tank line to give you more time to work. Fine tapered rubber plugs are best, maybe a tightly twirled compressed foam ear plug held in place by something like a toothpaste tube cap or fat Marr electrical connector, even a square of duct tape in a pinch. When done, switch the ignition on a few times to run the pumps and check for leaks afterwards wrapping a paper towel or tissue around each joint. It's a pretty straightforward job as long as you're prepared with a pan, plastic cups and paper towels to catch a little gas.
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Dave -still with 940's, prev 740/240/140/120 You'd think I'd have learned by now

It has been a long time since I changed out a filter on a 240. I can tell you about my experience with the 940's. I don't think they are all that different.

I remove the pump and filter as a unit from under the car. I have a piece of 1/2" dowel, an appropriate size hose clamp and a pan at the ready when disconnecting the hose from the tank to the pump. My experience is that fuel will run out in a steady stream- the hose acts as a siphon.

I "bump" the connection of the pressurized fuel line with an impact to loosen them. There are "flats" on the filter for counter holding but I would not use them. The filter material is thin and the connection can be difficult to loosen/tighten.

After the fuel lines and electrical connections are off you can move the unit to the bench. If you don't have new copper washers you should anneal the old ones and resurface them on carborundum paper (#180). Those connections that are secured with copper washers have a tendency to leak. I use an impact to again "bump" the high pressure connections to insure they are tight. It is maddening to think you are finished with this task only to find a high pressure leak when you start the car.

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Any twenty minute job is just a broken bolt away from a three day ordeal

The main fuel pump on my 1994 940t failed at 306k. It has been the only redblock Volvo that I have had to replace a main pump. I replaced it with a Bosch pump along with a Bosch filter.

I have always been happy dealing with FCPEuro. They offer lifetime warranty on the parts they sell. Links to pump and filter:

https://www.fcpeuro.com/products/volvo-fuel-pump-main-0580464068

https://www.fcpeuro.com/products/volvo-vw-fuel-filter-kit-bosch-1389562kt
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Any twenty minute job is just a broken bolt away from a three day ordeal

Is this the main pump or the in-tank pump? There is a huge price difference! Bosch is the OEM manufacturer of both pumps. That is the brand you should buy but your pump selection will be limited. Someone might correct me on this, but I believe Bosch main pumps for 240’s are NLA (no longer available). This is unfortunate as the main pumps are very robust and can run forever. Sold my 90 240 with 300k miles and its OEM pump. Read here about others with over 300k on their main pumps. If you need a new main pump I suggest checking with IPDUSA or FCP Euro to see which brands they carry. They are reputable companies.

If you need an in-tank pump the answer is still OEM Bosch if you can find one. You can save money buying an aftermarket brand but it won’t be the same quality.

Filter: Just buy one…

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Will I buy another Volvo??? We'll see....

I am pretty sure Bosch never made the in-tank pumps. But Delphi was OEM as was AC/Delco. Either of those would be a good choice. I have used Airtex for the tank pump in at least two different 240's and they are very dependable but I don't see them anywhere so maybe they're not being offered anymore.

Anything aftermarket is a crapshoot. They might be good quality but they might not. I once installed an MTC tank pump that lasted for less than a month.


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'79 242, '84 DL 2 door, '80 DL 2 door, '89 DL Wagon, '15 XC70 T6 AWD

Actually, I didn't think Bosch did either. I did see it on some website. I'll check later. You know what they say about believing everything written on the internet....

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Will I buy another Volvo??? We'll see....