I've bought a new-to-me '89 240 wagon and now need to start fixing stuff.

The fuel guage reads either completely full or dead empty, depending on it's inclination. I suspect the sender is damaged or loose in the tank. Also - because I think I smell fuel inside the car - I suspect a rotted mount plate for the sender and in-tank pump.

What's the best way to remove the mount plate without buying the "special tool" mentioned in the Haynes manual? I expect I can lift a complete unit from a junker, preferably a sedan since they have easier access to the tank's top.

Thanks,
Bruce

Bruce:

I did this job not too long ago on my sister's 1990 240 wagon - real PITA. The top wire was corroded off - no reading at all. I bought two used sender units off of ebay and still have a spare, if you are looking for one. Plus I have two brand new scan-tech pre-pumps (don't ask how I ended up with two - lol).

I also have the IPD bung tool that removes the sender - it was invaluable as I hate messing about with fuel. If it reads full or empty it could be a bad ground?? I would check that.

My current 88 740 is showing signs of needing a sender, but of course it's a different unit! Never fails. But I have to put an oil pump in it first before I tackle the sender. Bigger priority.........

Bob Weber
Hamilton, Ohio 45013
59 Volvos since 1979

Bruce,
First disconnect the battery,then blow all the crap off the locking tab with compressed air.Soak the locking tab with PB Blaster,liquid wrench,or whatever you've got.after letting it soak in use a hammer and brass screwdriver(no sparks)and tap the locking tab counter clockwise to "unscrew it".Move the screwdriver to different spots as you go.That should do it.Careful lifting the unit out as I've dropped the float ball into the tank and had a hell of a time fishing it out.
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philvo '90 240 204k and a couple parts cars

Thanks. This looks good. I'll have to use lung-power for compressed air - unless I maybe still have that portable tank I had once. But I think it's gone. Lung-power is most likely what I'll use.

I'll look for a brass screwdriver - didn't know there was such a thing. Will I find one at an auto parts store??

Bruce

Bruce,
i was just suggesting brass because it doesn't spark, not sure if there is such a beast or not,I have used a regular screwdriver with success but I had the trusty fire extinguisher handy.I too used lung power to blow the crud off.
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philvo '90 240 204k and a couple parts cars