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Several months ago my in-tank pump failed. Every time the tank got low I could hear the main pump sucking air. No sound when jumping the fuses as per Art's fantastic tutorial. No big deal, I had a leaky tank around the filler neck anyway, so figured I'd replace it all. New tank is very nice, no more puddles at the pump...
At the time I installed a known good spare sending unit with pump (both were working when removed from 2nd 240 about 1 year ago). Turns out both are caput - fuel gauge showing empty, dead in-tank pump (that's the second dud if you're counting). Fortunately, I had yet another sending unit with pump, both with less than 1000 miles on them (had been purchased new and installed on old 242 just before it died and was parted). This one had been sitting on the shelf for several years, but I was saving it for just such an occasion. Threw it in and fuel gauge now works, but this pump as well - dead. That's #3. By now I'm a pro at squeezing the sending unit in and out of the small access hole on top of the tank. Yay for me.
I buy a used pump from a local Volvo only parts supplier. This one is tested and also nearly new. Install it and .... FINALLY! Relief! It works. It's so refreshing not to hear that disturbing whirring sound when the tank starts to get below 1/2 full. But, not so fast! Less than 2 months later ... in-tank pump #4 dies and I'm back to square one.
I'm annoyed. I want to buy a NEW pump that is going to last more than 1 month. Is this even possible? Can anyone recommend a reliable brand for replacement? Having read Art's piece, it seems aftermarket pumps are hit and miss, mostly miss. I really don't want to do this job for a 6th time in 3 months.
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