Just removed main fuel pump from the mounting bracket and disconnected the plasic fuel line from the accumulator (I've got a CIS system) but how can I get the plastic fuel line apart from the main fuel pump? The new fuel pump I got from FCP Groton needs the plastic fuel line connected to it but how do you get the old one off the old pump - the two electrical posts that stick up from the top of the pump prevent you from unscrewing the plastic fuel line. Any help would be appreciated.

Why BOSCH did this is a mystery. The Volvo manual says to grind the jaws of an open end wrench to about half its thickness (my estimate) and also the outer edges to make the fingers narrower. Seems to me I found a tool (vice grips?) with jaws that would reach around one post from the side instead of going between them. Whatever you do remember you are working on a system that generates about 70 psi of fuel pressure. Any leaks could be big trouble.

You mean the book is telling you to make your own tool in order to successfully install a part? That's friggen nuts, plain and simple. There's gotta be an easier way. I'm open to any other suggestions. There's gotta be an inside scoop or something in order to get this job done properly short of machining your own tool.

I looked at an old one in my stuff. The plastic line is totally gone, and shows that the Banjo fitting on the pump has a barb nearly 1" long.

I put the pump in a vise (alum. jaw pads) with the barb pointing down and the jaws just snug. Ths "cap" holding the Banjo to the check valve popped loose easily with a 19mm box end.

It didn't seem to strain or hurt the barb any, so I think you could do the same. Of course you have to get it clean out of the car. But if you put the hose vertical in the vise, with the pump horizontal, the cap shold come loose like mine did.

The whole end of the pump looked pretty solid, so I then snugged it in the big vise and took the check valve out easily with a 17mm deep socket.

Probably could have done the Banjo cap the same way.

Hope this is in time to help,
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Bruce Young,
'93 940-NA (current)
'80 GLE V8 (Sold 5/03)
'83 Turbo 245
'76 244 (lasted only 255,000 miles)
73 142 (98K)
'71 144 (track modified--crusher bound)
New 144 from '67 to '78
Used '62 122 from '63 to '67

My son just did the fuel pump on his 81 and ended up prying off the plastic cover of one of the electrical posts on the old pump to make enough room to get the line undone. I don't know if this is the only way or not, but that's what he did. I wasn't under the car with him, but he told me about it.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 244, 140k , auto.

Thank you!!! It worked!!!!!!!!

I basically followed your advice and pulled the plastic protective pieces off the old pump's wiring posts. This opened up enough space for me to use two open end wrenches to get the bolt and hose off.

The new fuel pump accepted the fuel hose and bolt without any problems. No need to remove the plastic caps. No need for two wrenches. It just slid on (with the two washers don't forget) and then bolted nice and tight.

Probably should have bought a new accumulator since I had to take everything apart anyway but oh well.

This is one thing I can advise people who need to replace the main pump on turbo models. It's a pain in the butt to disassemble everything and you have to disassemble the accumulator anyway so rather then bolting the old one back into place why not bolt in a new one?

Live and learn I guess..........................

Thanks for the feedback. Glad it worked out. After doing the job, my son decided that, on our 81 CIS systems anyway, which I think are set up like yours with the pump and accumulator next to each other under the car, it would be much easier to release one more connection, the one about a foot in front of the pump, and bring the whole contraption up on the workbench and do the exchange standing up with good lighting, etc. He said it's only one more connection to loosen in order to do this. That's my plan when I do mine. Thanks for the tip about replacing the accumulator. I don't know what they cost, but if it's not too much, I'll do that too.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 244, 140k , auto.