1996 Volvo 850 Turbo Wagon - Replacing the fuel pump module

In this video, I replaced a failed fuel pump module on a 1996 Volvo 850 Turbo Wagon. The process for replacing the fuel pump module is the same for all P80 chassis Volvo front-drive wagons. Vehicles with 3rd row seating will need the 3rd row seats removed in order to have access to the fuel pump module location.

[@kernplace37]

Great vid. Little tip: grease the seal, then drop the lock ring in boiling water for 5 minutes, it goes on real easy after that...

[@Backwardlooking]

Thank you. Purchased a fuel pump relay, fuel pump and new gasket for my Volvo 850 Estate purchased new in 94 as spares!. 👍🏻🏴󠁧󠁢󠁥󠁮󠁧󠁿

[@eddiemitchell2781]

Wow - That was the best explanation for replacing a fuel pump & well filmed! I appreciate the extra time you spent with each step of the process.

[@alangale9768]

Exactly what I'm doing now. Great helpful Video

[@luigicipressimightyena8486]

... Small tip. Disconnecting the pipe fittings in this way can lead to breakage of the fittings themselves. You need to lower the rubber ring, so as to reveal the clip underneath. Then, with the index finger and thumb of one hand, press on the clip: with the other hand, press DOWN on the fitting. Incredible to say, and against logic, but, by doing so, the fittings come off effortlessly and without problems. Volvo V70 TDI 1997. The float is the same, only without the integrated electric pump.

[@jlolson53]

Very good video AK. However, I have a suggestion: a mini-pry bar to remove the rubber caps. Just used it on my Volvo (97 850) and pried them neatly off in about five seconds. :) The pry bar's about 6" long with a nice bend for leverage (great for removing nails, too;-). Also, loosened the retraining gasket with a light tap of a screwdriver by a hammer, then turned it easily out by hand. Anyhow, best vid on this subject I've seen (with apologies to Robert, the "Black Swede," whose Volvo repair videos are excellent as well)

[@srgest9653]

Thanks for an easy explanation! Replaced my fuel pump today!

[@vargbmx]

This help alot.! Thank you ! Now can i do it the same on my Volvo 🤗🥳🥳

[@imamymay]

Great video. I've found 2 other videos on here where guys disconnected frame parts and dropped the tank just to get at the fuel pump. I have a 98 v70. I assume it has the same access port.

[@AKJeeper]

As long as it’s a front wheel drive model, you’re golden. AWD models are a completely different story.

[@imamymay]

@@AKJeeper ok, that explains it. Yes I have manual transmission FWD 1998. I think the fuel pump is bad. I can hear it sometimes when I firs turn on the key but sometimes you can't hear it. Like it's working intermittently. BTW, I think it's really dumb that volvo would not make the same parts accessible on the AWD version. weird.

[@AKJeeper]

@@imamymay if you haven’t replaced your fuel pump relay, now is a good time to do so. Volvo’s AWD P80 cars were kind of cobbled together. Their later P2 models were consistent with giving an access panel for both AWD and FWD models.

[@deewilliams3280]

@@AKJeeper Any chance you could direct me towards this different story please?! 1999 V70 AWD (turbo). I'm needing access to both the pump itself, and to figure out where the relay is...

[@mc60617]

Great video once again. I’ve never liked those in-tank pumps on any car.

[@AKJeeper]

Thanks! I miss some of the earlier days of EFI when vehicles had a fuel pump located external to the tank. Mercedes, VWs, Volvos, etc from the 70s-90s often had these externally-mounted pumps. Still, having an access panel like this Volvo is a lot better than having to drop the tank like on a lot of other vehicles.

[@mc60617]

AKJeeper I agree. External pumps are way better. Quicker to change and you don’t end up breathing as much gas fumes.

[@redbeak1453]

Super explanation. I have a couple of questions as my 96 850T5 fuel pump is starting to make a grinding noise. What did you use to lubricate and seal the ring? How do you torque to spec with a oil filter wrench? And what is the torque? Also as these cars are getting older, wouldn't it be a great preventative to change the fuel hoses? I have a 77 VW Bus, and after just 12 years some of the hoses just deteriorate. Thank you so much for your clear presentation!!!

[@johnallisonpereira2389]

Thank you for the explaination. Now it gives me confidence of doing it myself. By the way is the fuel pump similar to volvo 850 glt?

[@Marhowl]

All Petrol fuel pumps are the same :)

[@jakominasi7494]

Tenks for dis vidio is reale super vidio e multo utile Grazie a voi

[@Buechse._Pusteblume..]

Thanx!

[@73SDR]

It's Del-fy, not Del-fee. It's a former division of GM, and has since split into two companies, Delphi Technologies (which was then purchased by Borg-Warner) and Aptiv.

[@AKJeeper]

Thanks for the quick lesson. I knew they were affiliated with GM at one point in their history, but it seems everyone in my area pronounces Delphi differently. Now I know! :)

[@diegaulle9143]

Great guide. Could you please tell us where the tank sending unit is concealed? Thanks!

[@scottmiteen4772]

It right in front of the fuel pump access panel. There's another access panel for the sending unit.

[@vaughanrolls2346]

What is the other panel ; smaller than the fuel pump panel?

[@augustinustriyanta1389]

Hallo from Indonesia

[@michaelsliwinski8044]

Bravo!

[@peterhandelson1193]

What brand is the spark plug wire puller tool?

[@AKJeeper]

I believe it’s a Lisle 52990

[@peterhandelson1193]

@@AKJeeper someone said that those fuel boots are designed to be pried up from the bottom. And that when they are pried from the bottom they self release. What are you thoughts on that?

[@AKJeeper]

@@peterhandelson1193 These are quick connect lines, it takes an upward motion on the lock ring to get the coupler to release. You could pry the lock rings from the bottom, but you run the risk of breaking the quick connect coupler if you do it this way (aging plastic and all). If you look closely at the pliers, you can see that I am grabbing the lock ring and using an upward and twisting motion at the same time. I find this method to be a little more gentle, though it might take just a little longer than if you were to simply pry up on the lock ring with a pry bar or something. Like they say - there’s more than one way to skin a cat.

[@babyhuez597]

I thought I had to drop the rear crossmember and gas tank to get to the fuel pump!?

[@AKJeeper]

Nope. Not on a front-drive Volvo 850 or V70/S70. You have to drop the tank on AWD P80 Volvo cars, though.

[@bradtouchton4816]

What is the extra wire coming off of the cuel pump harness i have mine and its not working and idk of it has to do with that wire or nor

[@AKJeeper]

A lot of the replacement fuel pump assemblies come with the extra wire. I have yet to come across a P80 chassis Volvo that utilized this extra wire. Have you looked at the fuel pump relay, these are high failure rate items now that these cars are approaching 30 years old.

[@bradtouchton4816]

@@AKJeeper well i have power coming to the pumps harness just not getting fuel mine is a 97 850 brand new pump too

[@AKJeeper]

@@bradtouchton4816 If you’ve got good power and ground at the fuel pump electrical connector (I have an old power window motor I use to make sure a circuit like that can carry a load) , it’s looking like your pump is at fault. Can you hear the pump running at all? It’s rare - but I have come across bad parts that were brand new in box.

[@bradtouchton4816]

@@AKJeeper yeah no when i first got it we heard it kick on and since then it hasnt

[@AKJeeper]

@@bradtouchton4816 check pin fitment at the fuel pump electrical connector. I’ve seen some where the terminals got spread out and did not have good contact. What brand of fuel pump did you use?

[@darknightftfw6249]

Hey question for you. Where did you find your fuel module?

[@sparkie5571]

amazon, or summit racing. delphi FG1123

[@scottjames51]

Your a good man but this is just a 5 minute job using just 1 tool and that's a screwdriver or what u Americans call a flathead there is no need to lift up and remove that rear panel by the seat u can get to everything without all that extra labour i have change plenty of these but hey what do I know..