Wednesday, November 13, 2013
How to Install a Fuel Pump on a 1996 Volvo 960
The Volvo 900 series is a line of mid-size cars produced from 1990 to 1997. The 1996 model was equipped with a 6-cylinder 2.9-liter engine. This vehicle used electronic fuel injection, which requires a high-pressure fuel pump. The fuel pump in a 1996 Volvo is located on top of the fuel tank and is accessible from the rear passenger compartment.
Instructions
- 1
Attach adapter 999-5484 to fuel drainage unit 981-2270 with the fuel drainage unit in the closed position. Remove the cap from the fuel pressure valve on the the fuel rail. Connect the adapter to the fuel pressure valve. Open the fuel drainage unit to relieve the pressure in the fuel pressure system.
2Raise the vehicle with a floor jack and support it on jack stands. Remove the cap for the fuel filter valve and connect vent hose 999 5480 to the fuel filter valve. Drain fuel into a gasoline container for about 2 minutes. Disconnect the vent hose and replace the valve cap. Lower the vehicle and disconnect the fuel drainage unit from the fuel pressure valve. Replace the cap on the fuel pressure valve.
3Disconnect the cable from the negative battery terminal with a socket wrench to avoid starting the engine. Pull back carpet over the right rear wheel in the rear passenger compartment. Disconnect the electrical connections for the fuel pump.
4Disconnect the quick-connect fittings on the fuel lines to the fuel pump and detach the fuel lines. Turn the retaining nut for the fuel pump counterclockwise with tool 999-5485 to remove the retaining nut. Disconnect the fuel pump and rubber seal from the fuel tank.
5Apply a thin layer of petroleum jelly to a new rubber seal, then install the rubber seal. Install the new fuel pump with the heater connection facing the right side of the vehicle. Tighten the retaining nut onto the fuel pump to 30 ft. lbs. with tool 999-5484 and a torque wrench.
6Connect the electrical connectors and fuel lines to the fuel pump. Put the carpet in the passenger compartment back into place. Connect the negative battery cable with a socket wrench. Start the engine and check for fuel leaks.
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