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Dear Dave Stevens,
Hope you're well and stay so. According to the Volvo Pocket data booklet - Cars (700, 850, 900) 1991-1995, fuel tank capacity for 940s (Sedans and Wagons), 1993-1995 was 75 liters. For 960s, the tank capacity was 80 liters, except for the 960 wagon (1993-94), which had a 75-liter tank. Send units from 1992 and earlier models will fit in 1993 and later cars, but have a barrel too short to reach the bottom of the larger tanks, so will not be able to use all of the fuel in the tank.
As to fuel pumps, the pre-pumps used in 1993-94 normally-aspirated 940s draw 3-4 Amps; pre-pumps in turbos draw 5.5 Amps. As to main pumps - whether mounted externally or in the fuel tank and whether turbo or normally-aspirated - all have the same capacity: 130 liters/hours at 12 volts and all draw 6.5 Amps.
Thus, while there are several part numbers for these pumps - both Bosch and Volvo - the pumps seem identical in terms of their capacity to move fuel.
I've replaced a Rex-Regina fuel pump and send unit at 141K miles and a '95 940 fuel pump and send unit at 71K miles; the pump was fine but the send unit was not reliable.
Hope this helps.
Yours faithfully,
Spook
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