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Broken Wire problem...... :( 700


negative good buddy, time to replace your sender.

the design of the volvo fuel sending unit/arm/item is flawed. basically there is a 1-2mm gap between the white marshmallow connection thing and teh actual plate. Water and gunk from under the car seeps into this gap and, over time, rots the connector off. You generally notice this when your fuel gauge starts phasing in and out or just plain dies (you don't notice it when the pre-pump dies because you can easily drive without a pre-pump... the main pump just gets louder).

You might be able to jury-rig something, but I wouldn't recommend it since your dealing with the fuel tank's structural integrity, etc. The new sender will include the plate, the arm down into the tank, and the wiring that comes off teh plate/cover to the ground (inside driver's rear wheel well) and the pick-up to the dash on the back of the same wheel well.

Not sure what year you have since you failed to indicate it, but prices vary for teh different designs. I got mine for about $120 online (part lists for $230) from http://www.importeccatalog.com. Free shipping and it arrives in two days. The replacement is made by VDO and is identical to the original in every way. BTW, save the little plastic brackets from the existing pre-pump holder, etc., you'll need them for the new one since they aren't supplied. I would also suggest you replace the fuel screen and the fuel hose between the pre-pump and the arm/pipe of the sending unit.

easy fix, just go slow, remember your working next to highly flammable gasoline (i.e., this is a no smoking job), and be gentle with the sender arm (you have to work it to get it in). Oh, also look in the tank before installation to see exactly how it should sit in the middle ring.

good luck,
rt






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