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I’ll make a long story short (there’s a lesson here!). My wife’s car wouldn’t stay running for very long. So I tried and tried and eventually traced it to the fuel filter. Replaced it, but was too late - burned up the pump trying to get the fuel past the clogged filter (this was Sunday evening). Of course, by Monday, volvo had the pump - $200, and a couple independents had a pump for a little less than that, but I wasn’t going to pay that kind of dough. So I called HI/LO - they ordered it - shoulda known better. Wrong pump, wrong design (I have the Regina style fuel system - one pump - and it’s in the tank.) Luckily, I was able to call John at Volvo Parts Independent (800) 303-6544 in Houston. He got the correct pump to me the next day. Now for the info I wanted to pass on...
IT seems like a pretty straightforward job, and for the most part is. Two obsticles - the pump assembly was wired straight into the wiring harness. There were no plugs. Nothing serious, just annoying and un-volvolike. The biggest hurdle was getting the pump assembly to fit back in the tank. There is a large, plastic, oval ‘cap’ that threads onto the plastic fuel tank - This cap is what snugs the assembly to the tank. AROUND the assembly is a rubber seal (about 2” deep) that sits between the assembly and the tank opening wall. I hope this makes sense. It was a bear. It wasn’t until my neighbor came over and got underneath the car, and I got out the vaseline (no funny stuff, I was crammed inside the trunk) to coat the seal, did we get the it to seat. IT took three hands. The secret was not to do the obvious/easier route and put the seal around the assembly, but to seat the seal in the opening and push the assembly through it. I hope this helps!!!
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