My car stalls when the tank is ~1/2 full, I've got some time on my hands over the Thanskgiving holiday so I figured I would attack the problem with the assumption that the short length of hose connecting the pump to the fuel line is bad...

With the pump out, I am planning on doing the short hose and also the sock and would like to be prepared. Here are my questions:

1) What are the hose dimensions?
2) What else besides the sock, hose and new tank gasket can I do with the pump out?

Thanks,
Zuda

Just pulled mine out and found the bellows style hose in there had a long
tear in it. If the hose is failed that badly I would think you would hear
your external pump fighting harder. At least on the 84 the pump draws through
the filter from the bottom of the tank and pushes it up through the splice into the outlet steel line. If the the splice line fails (like mine) I just dont
see how any priming of the outlet line is taking place at all! The internal pump would just sit there and run in circles so to speak.
I replaced mine with regular fuel line.
If my evaluation is off for some reason I would love to hear why..
TIA
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vw bus site - http://www.geocities.com/vw_bus_74/index.html

My suggestions would be as follows. You're in there, why not replace the pump for an extra 30? How many miles are on the current pump? Get a new Sender gasket and a new lock ring ("bung nut") because you'll probably bend the hell out of the old one unless you're very careful.

The hose size is 5/16" and I would clamp it as well.

Get some PB Blaster and soak it (the bung nut) the day before. Things will come apart much easier.

Good Luck
Marty

Thanks everyone for your suggestions.

Marty, I'm the third owner of the car, no records to speak of. I'm assuming that the pump is the original with 165k miles on it. I just might take your advice on the new pump...

One question, the sender gasket...is this the same one that seals with the bung nut?

Zuda

Yes it is. It's basically a large O-Ring about 3 inches in diameter. FCPGroton.com has the best prices on this stuff to my knowledge. Also, I don't know how soon you'll be doing this but, IPD sells a bung nut tool that works like a charm. Saves a ton of time and hassle and will cost you around $30 with shipping. If you think you'll be driving 240's for a long time it might be worth the investment or if you have friends with 240's that would go in on it w/ you.

good luck
Marty

There are two grades of fuel resistant hose. The lower grade ("e:?) will buy you a couple of years but it will eventually swell and slip and cause problems. It will buy you a couple of years though. If you can find the higher grade hose ("f"?) it will be more permanent. Best is the Volvo hose.

You can check the electrical connection and make sure it's not corroded.Mine(sender/prepump) failed because the ceramic thing broke off.
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philvo

Thats where mine failed as well. I was surprised at the corrosion inside the insulator. On the replacement unit, I painted the ground tab and surrounding area with GC Electronics Red Insulating Varnish and also wrapped the connector with (hopefully) moisture resistant electical tape/putty.

'92 240 wagon 136k miles

The hose diameter is about .250 BUT, it is a custom kind of hose that is on there. I don't think you can just cut a piece of gas line and toss it in.

What you mentioned is about all. You can eyeball and make sure the tank isn't rusted up internally.

Clean the heck out of the surrounding area before you tap off the "Crown " nut. You will have years of grime there that you wont want falling into the tank.

I used a little Vaseline on the metal Crown nut when reinstalling.
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'75 Jeep CJ5 345Hp ChevyPwr and two motorcycles: it wasn't Volvos safety , it was Longevity that sold me

To the best of my knowledge, the newer cars have an accordian style hose on the pre-pump. The older ones have just a piece of fuel hose. I just put a short piece of high dollar FI hose in there and have had no problems. Just to be sure, I clamped it at both ends but the one that came out was not clamped.

Bob
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82 intercooled turbowagon 235K