How To Replace 1986 Volvo 240 In-Tank and Main Fuel Pumps

In this video, I'll show you how to replace both the in-tank and main fuel pumps on my 1986 Volvo 240 DL. Both pumps and everything needed were purchased at IPDusa.com and FCPeuro.com. The whole job took about 4 hours which included filming.
Main fuel pump time-stamp: 4:56
Main pump:
www.fcpeuro.com/products/volvo-fuel-pump-main-0580464068
In-tank pump:
www.fcpeuro.com/products/volvo-fuel-pre-pump-in-tank-3507436
Bung nut removal tool:
www.ipdusa.com/products/5427/106653-fuel-tank-bung-nut-tool
Other tutorials:
"How to fix a 1986 Volvo 240"
kzbin.info/www/bejne/fGWQnIiXeLWcgLc
"How to replace a Volvo 240 transmission mount"
kzbin.info/www/bejne/iH69o6aIo8l1o9k
"How to replace Volvo 240 brake pads"
kzbin.info/www/bejne/fIWcfKZ7aKmlm9E
Thanks for watching! Don't forget to comment and subscribe!

[@TheAwkwardBanana]

Your guides are easily my favorite 240 guides on KZbin, very confidence inspiring!

[@bmwtwo13]

very nice detailed instructional video bro! I have a 89 240 and I need to do some maintaining. Your vids are very helpful to me. Keep em coming!

[@davepak5509]

Ive got an '89 240 as well, need to get her up and running again

[@GraeSkyeStudio]

Thanks man! Gonna be tackling it soon as I’m in the middle of hobbling home.

[@spacesuitor]

BUNGNUT BROUGHT ME HERE.

[@danb37]

You described my 91's 240 car problems exactly! Thank you for this video. And ironically, because of hurricane Urma, I was waiting for my "new" used 2002 volvo V70 to be shipped from VehicleVille a few extra weeks!

[@mgaquer]

Dan B glad you were safe from Irma and glad I could help u fix your car probs lol

[@Crack.exe.]

@@mgaquer hi i need really fast help.. my Volvo 240 1986 gle lost alot of power and i would suspect that the fuel pump or something with it is bad but im not sure. Could it also be the fuel Lines clogged or the carburator being clogged or carburator oil being low? im not really sure if those things can make such a big differense because i almost got no power at all its drivable but accelaration is bad. i need to use this car on saturday this week and if not im kinda f**ked

[@mgaquer]

@@Crack.exe. have you tried turning the car off then restarting? ive had an issue where after some rain storms, id go to drive and there was no power, so id put in neutral while the car was still rolling, turn key off then restart the car and put back in drive and it would fix the issue. It turned out that my fuel pump relay was shot (behind the glove box)

[@Crack.exe.]

@@mgaquer thanks ill test d that

[@michaelppaull]

its a bung who now? haha thanks for the vid! diagnosing some fuel related stuff on an 84 right now.

[@daviper865]

Hey i appreciate all of you're video's about the volvo 240 dl i have a 1987 240 dl and you have helped me a lot with you're videos ,Thanks and keep posting what you know about the volvo ..appreciate it

[@Thepreacher1960]

Very professional job. Well done

[@bohemialite6371]

Dam boy you are just the right man for a promotion plus if you do the same job at your work great job.

[@THEFALLEN2231]

Nice vid! If only it was out when I had to replace the in-tank pump!

[@ootoot2152]

Cool video! I have an 88 DL and am going to replace the fuel sending unit itself soon. I believe the board that tracks the fuel level with the rising and lowering ball is completely worn out and I'm getting inaccurate fuel readings, so this video is very helpful!

[@jimholmes2555]

At least Volvo provides an access hole. Ford, GM and Chrysler you need to drop the tank (Full or Empty) to the ground to get to the pump.

[@RodTDavies]

Incredible watching you bro cheers

[@curtismcmahon6463]

Thhhaaankkk youuuuuu!... this helped me do my in-tank pump without any hiccups 🤘😎🤘.... bung nut

[@victormolina6860]

Excelent video.

[@WHATSUPWATSON]

Great video!

[@gersongtrz]

one of the most random playlists I've heard mate, from 2PAc to Metallica hahahaha cool stuff. Thanks for the vid, I will do this soon, my 240 is having issues going uphill :/ lacking power

[@chknjo]

great video!

[@sparxxraps2538]

great vids subbed

[@hawkesworth1712]

I remember doing that to my 240GL about 30 years ago. Volvos of that era just didn't like an Australian summer.

[@ranchovistadenada]

Nice video!

[@amiravollendorf6630]

I have the same power issues and originally I thought it was my spark plugs which I changed out and it help some but now my car will try to ignite but won't fully. I'll give this a try, hoping for the best

[@thomasmilano9870]

BUNG NUT, BUNG NUT, BUNG NUT! Hilarious, thx for the vid, I will be doing mine soon. '89 240DL wagon

[@carterlink2424]

Great video helped me out aton

[@bluesky-vw1jo]

nice video

[@eRic-oy9cu]

Getting that in-tank pump out is a NIGHTMARE. If your're good a puzzles and are really patient it's the job for you.

[@TurboWorld]

Sweet!

[@jayananda3866]

keep it up mam!

[@jamesselback8691]

1:59 lol thanks for that

[@killcode03]

What is the third branch on the sending unit? And did you cap it?

[@waskyhenry3132]

Matthew. Wow!, that was fantastic. It looked like a class room lecture. I have a 1987 240 DL. 2nd owner. I've owned the car since 1989 , although it was stored between 1993 and 2013. I put it back into action in 2014 after changing the two fuel pumps and a complete tune up. The car is a classic. The Volvo dealership loves it every time I go in for a part. I'm now having a problem with sluggish performance and slow start. Any suggestions? Thanks.

[@geoffreycarter3981]

That fitting that you are tightening right at 6:58 at the output from the pump leaks for me like crazy. I destroyed the old coupler hose trying to get it off when replacing my filter so I bought a new one and it leaks like crazy. Is there supposed to be a washer there? Or are you just supposed to crank it down incredibly hard? i feel like I have a faulty new coupler...

[@moonglow1158]

Did fuse 6 keep blowing bc that electrical connection at the pump is bad ?

[@sharkT3]

Hi Matthew, i would be cool if you place a link for the other gaskets & items like the ring nut from the fuel tank..i almost missed that but i had to review the video to make sure i wasn't missing stuff. much appreciate you are taking a time and record this vids. Thanks for sharing bro!

[@mgaquer]

FCPeuro.com or IPDusa.com are where I ordered everything. They are really helpful and their customer service is top notch.

[@motopumpkin3129]

Why didn't you clean all that stuff off first, so much crud fell in the tank 😨

[@mgaquer]

NICHOLAS SINRAM that was right before hurricane Irma almost ripped us in Florida a new arsehole. Plus I prob ate a big bowl of dumb-arse that morning 😂😂😂

[@rowleks7102]

gj bro

[@jessezink4802]

hope you’re still active. how tight did you put the banjo bolts ? did you have any leaks after checking for leaks.

[@mgaquer]

Jesse Zink I’m still here! I tightened it a 1/4 turn and no leaks man. Good luck!

[@anticat900]

Just been doing the same with my volvo, the main issue is getting the pump back in the tank. My sock and float came off in the first and second attempts ☹️. Had to use a child to fish out the bits from the tank which is probably illegal bit only their hands fitted 🙂

[@jmatthews3072]

Where do you get that bung nut tool

[@andrewpeterkin4510]

Did this job improved your car's performance? I have a 1990 Volvo 760GLE with ~250k miles and both pumps and filter have never been replaced. I am getting rough idle, and at times poor throttle response. I am going to do the main in-line pump and filter first. I like your use of the padded needle nose vice grips to pinch off the flow of fuel when disconnecting the fuel lines. But after removing the clamps from the fuel hoses, can you share any tricks for sliding off the hoses without damaging the hoses. I have noticed that the hoses on mine are very hard, so by crimping it, I am concerned about cracking it, in which case the entire hose may have to be replaced. --- I will appreciate your comments. Thanks.

[@mgaquer]

Andrew Peterkin the rough idle could be a number of things. I’d start with the basics first like plugs and wires etc. But after my pumps were replaced I didn’t notice intermittent hesitation in turns that sometimes would happen. In regards to the fuel lines, I’m not sure what you’re asking? I used the vice grips with rubber to clamp off the fuel. Loosened the hose clamps by the pump then simply slid hoses back onto new pump. Make sure u pull fuses 4 and 6 then let the car run til it dies to relieve pressure. Feel free to email me, my email or social media is in the description.

[@nostart-jael4416]

Hey man these vids really helpful. But i need some advice. My 86 240 dl has a problem where sometimes in the morning it wouldnt start. It started happening more frequently. And rn im left with a car because now it doesnt wanna start at all. Diagnosis lead to either a shot pump or a bad relay

[@mgaquer]

NoStart-Jael make sure battery cables are tight, check fuses 4 and 6 for corrosion, check the 25 amp fuse in engine bay by battery against the fender panel, check fuel pump relay.

[@nostart-jael4416]

@@mgaquer i checked everything today after school and she fired right up after i replaced the 25 amp fuse. It was reslly corroded. But thank you for the advice

[@jmatthews3072]

On the in tank pump, which wire goes to which on the two wire QD

[@savannaswildnatureworkshop7810]

curious....when you put the in tank back in place you used the old bung nut..not the shiny new one...what happened? Savanna

[@mgaquer]

I forget if I put the new one back on after the video editing was done. But I think I put it all back just to realize I forgot to use the new bung nut

[@alexstepanski]

Casually working on my Swedish automobile.... “what they really want from mah nigga!?!?” Playing in the background

[@vigoasplash]

I saw your video. My 1986 Volvo 240DL was diagnosed with replacing 2 gas pumps and filter. Can you tell me how much would it cost for this repair before I take to a mechanic...thank you.

[@johniboi1789]

Might be too late but. All in all. Keep in mind I also got trans fluid oil and oil filter. I was in about 300$ Both pumps and the filter. And the strainer because no auto part store had the filter with a strainer. Cost me about 180$

[@moonglow1158]

What is the symptom of a torn fuel sock?

[@CaptainBlackBread]

Can you make a video on how to replace the fuel filter?

[@johniboi1789]

Those two can you saw him take from under the car. Are a fuel filter and a fuel pump. That giant one is the filter

[@discerningmind]

Good video. But I would have brushed and vacuumed the outer area of the in-tank pump before removing it. There must have been a lot of crud that fell into the tank.

[@mgaquer]

discerningmind thank u!

[@davidmason3566]

Anyone know how to open the trunk if it's stuck? The whole is the backseat is way to small for me to squeeze through

[@PUBL1K3N3MY1]

thnks Mat PRettty KOooo

[@thehorseman1806]

I'm doing the same exact repair on a 91 volvo 240. Where did you buy your replacement AND where did you get the tool that attaches to your drill?

[@mgaquer]

FCPeuro for most parts since i live in Florida. If they don’t have inventory, then IPD USA.

[@thehorseman1806]

@@mgaquer yeah my friend, who owns the volvo, and I have discovered that without that tool that fuel pump may be impossible to get out

[@mgaquer]

@@thehorseman1806 well good luck yall

[@MGreen-vz6yb]

Did he drop the tank or is he inside the car?

[@abelardosanchez8608]

Turbo it and lower it and slap wheels on it 😭❤

[@nikolai502]

My ft engine cuts the gas during full throttle in 2nd and 3rd gear, i'm suspecting the fuel pumps and pressure regulator

[@ZainZain-ni2yw]

ارجو توضيح عملية صيانة فان التبريد

[@kennethlaycock4724]

I see it, but I find it inconceivable,that you didn't use a vacumn cleaner to remove the loose debris.

[@andxx0r_the_second671]

Where did you get that BUNG NUT BUNG NUT BUNG NUT removal wrench? That looks like a really handy piece to have!

[@mgaquer]

andxx0r_the_second IPDusa.com. If u email me I can sell u my old one

[@andxx0r_the_second671]

I already bought one from ipd! Good thing too, because my wiring has rusted right off the old sender and it’s got to come out.

[@danielebbeling4056]

How much time would you allow a non-professional to accomplish changing these out?

[@mgaquer]

Daniel Ebbeling at least 12 hours just in case u need to run to parts store, breaks in between to eat or drink, or in case u run into issues. But if all goes well, I’d say easily 6 hours. I’m the type that likes extra time for myself

[@danielebbeling4056]

Matthew Gaquer Thank you , Matthew! I have a 93 940 with a leaking main pump. I will figure a weekend after the parts arrive. Lots of rust on my tray as it is a NE car.

[@MarkJones-si2bb]

How long to change both for an experienced 240 mechanic?

[@mgaquer]

Under 2 hours

[@MarkJones-si2bb]

@@mgaquer Thank you!

[@crossclaim1]

Hi, I can't find a video on how to replace the license plate light on a Volvo 240 4 door. I got the covers off but can't pull out the bulbs from the wire contraption. Help! I'm a chick. Thanks!

[@mgaquer]

Haha I forgot how to do it! Have u checked turbo bricks forum

[@crossclaim1]

@@mgaquer Thanks, I will check.

[@victorpelini5995]

Mine failed today at moms house, wasnt that hard to replace thx god I had the part but sadly the new isnt working either. I got 9V at the connector in the trunk while I have 12.5 at the fuse box (this is weird) I dont know what wrong, maybe a bad Relay, a worn cable. Its an 88 sedan

[@rickyjaypeterson4704]

Matthew I like your style brother, no shade, in the yard, just like Pops used to do. In Vegas No choice but to seek shelter BOB out there all day much like Flouda. Big Orange Ball aka the sun. Any audible ques or clues why your swapped out the pump. I hoping someone has a video with this BOSCH European Scientifically Engneered Crafters from Thor's Hammer pump Hum on file, I got a buzz much like a bad doorbell or door buzzer. I hope that's the bad sound not the "Hum" but I'd like to know before I go. Any help would be greatly appreciated. Sounds byte/bite recording. Be well, Stay safe. Sorry Main pump plz.

[@victorhenneberg6790]

is your car carb or injection

[@mgaquer]

It was fuel injected

[@forwhatitsworth364]

Nipple bung nut clamps

[@christopherwhitson6064]

Are the "pre-pump" and the in-tank pump two different names for the same pump? I'm considering doing the iPD upgrade when I change mine. www.ipdusa.com/products/5799/111016-volvo-in-tank-fuel-pump-upgrade-kit-aftermarket-7845k

[@mrpete9958]

Yes. Some also refer to it as the low pressure pump.

[@MrDeadline34]

Well the 740 sedan is a real pain my wagon was so much easier

[@StreetForged]

"Loss of power" how can you even tell? Did the 0-60 go from 15 seconds to 20? Lol my 240 is completely gutted out and it's still so slow I'd be afraid to race an old base model 90hp Civic

[@mgaquer]

Street Forged Yea the windshield wipers got slower so I assumed I’ve lost power. Sucks... 😂😂😂

[@StreetForged]

Hahaha It doesn't matter if they're slugs, somehow they're still pretty endearing to drive, though I bought mine on cut springs so I've never gotten the opportunity to drive a completely stock one :/

[@michaelhilber8284]

Shoulda blown that crap off with compressed air, before removing that fuel sending unit. It was dirty on top.

[@sindhimaginto7595]

Matthew perfect video what is your email please

[@ThePolaroid669]

Please explain how to 'use' my due diligence. I can DO my due diligence, but haven no idea how to 'use' it. Incorrect english!!!!

[@45rOfficial]

Useless

[@jmatthews3072]

Where do you get that bung nut tool

[@mgaquer]

FCPeuro.com or IPDusa.com I forget which one had it

[@MGreen-vz6yb]

Did he drop the tank or is he inside the car?

[@mgaquer]

inside the trunk