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2002 XC70 Fuel pump retrofit with P80 pump

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

precopster
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precopster

2002 XC70 Fuel pump retrofit with P80 pump

Post by precopster » Fri Oct 10, 2014 4:22 am

I wanted to see how complex the P2 fuel assembly is after being quoted over $380 locally for a Bosch 30761743 which includes the sender and the pump as one unit. I didn't want to wait 10 days for a pump assembly from Tasca (just over $209USD which is not a bad deal at all) so I decided to see how different a P80 (Gen 1) pump is. I found a seller locally selling Bosch pump 0986 580 979 to suit P80s for $78 AUD. The ad claimed it suits C70s up to 2002 with the B5244T engine so it must have similar specs.

PARTS/TOOLS REQUIRED:
1) Hammer (my favourite tool)
2) 25cm (9 inches of submersible fuel hose)
3) Bosch pump 0986 580 979 comes with 2 X quality clamps (other parts in the fitting kit won't be needed)
4) 1 X axle bolt or 10mm threaded rod to push pump out of filter fixture
5) Gauze filter (I used an Aldi shopping bag pre-tested for fuel compatability)
6) High tensile spring 8.6mm wide to be inserted into submersible fuel hose (one of these can be stretched for 2 installations)
7) 10mm and 14mm sockets and ratchet
8 ) 2 X large flat screwdrivers for fuel hatch removal (thanks jimmy57) or suitable tool
9) Pliers
10) Adjustable monkey grips for fuel clip removal
11) Stanley knife (for old plastic hose cutting)
12) Small flat blade screwdriver
13) Scissors (to cut new gauze)
14) Paint brush and vacuum cleaner (to help remove dust/debris before hatch removal and inside pump housing)
15) 32mm ring spanner or ring socket (to locate pump back onto old gauze filter housing)
16) New fuel filter
17) Spare space for item I forgot to mention haha

Of course I removed the seat cushions first by folding them forward and releasing the red clips. Then I pried on the narrow board between the seat backrests and the luggage boards. There are clips that just require prying here. If you don't have the 7 seat option just lift the luggage board up and slide it closer to the tailgate.

Another important step is to disconnect the battery as the connector to the back seat will trigger an SRS code.
20141009_211530 %28Large%29.jpg
The new Bosch fuel pump for P80 series
20141009_211530 %28Large%29.jpg (70.72 KiB) Viewed 607 times
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Remove the carpet keepers X 2. I used a large flat blade to coerce them
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Pull on this bolster and it will eventually come out
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Remove this connector
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Remove this 14mm bolt in order to remove the large seat backrest
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There are 2 x bungee cords to unclip from the backrest
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Sound deadening material peeled back and finally we can see the hatch. Backrest is upside down in footwell
20141010_112428 (Large).jpg
Hatch cover removed exposing the pump assembly. The port is very dirty and needs a clean
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The port cleaned up with a paint brush and vacuum cleaner
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I found it easy to press both clips with one of these
20141010_112912 (Large).jpg
Touche. Engard Dartanion!!
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Finally pulled it out. It doesn't come out easily and is tied to the sender on the other side by wires
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Showing the 2 tabs to depress before removal of the sender resistor (press both in and pull up with pliers)
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Two tabs to press and the sender resistor can be removed
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There are 3 tabs like this around the housing to press in and then pull the pump upwards
20141010_114340 (Large).jpg
The old gauze filter needs to be removed because in this case I couldn't pry the pump out
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The pump removed awaiting further extraction (notice I have already torn the gauze filter away)
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Forcing the old pump out with a 1999 plus axle bolt (end of pump is metal)
20141010_120602 (Large).jpg
Pump bodies are both 38mm
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Tops are a very close match
20141010_120612 (Large).jpg
Ends are near identical
20141010_120743 (Large).jpg
With good clean Aussie fuel, pumps should last about 60,000kms !! I can now build a sandcastle!!
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Housing assembly after pump removal
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Hmm my wife won't miss this shopping bag
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Place some assembly grease on the tip of the pump inlet and hit the pump onto the gauze housing (gently)
20141010_144934 (Large).jpg
Please note that the ties are not in their final position to clear the housing
20141010_145004 (Large).jpg
The original hose can't be removed without breakage. I used a Stanley knife to slice it carefully
20141010_180445 (Large).jpg
Zip ties @ 5 oclock to the protruding plastic piece
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I used 2 zip ties for safety; hope they last
20141010_181219.jpg
Instead of using this much like I first did, it's best to cut the spring in half and stretch it to the length of the fuel hose
20141010_181336.jpg
Clamp the submersible fuel line to the new pump
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Insert stiffening spring (you can use twice the spacing I used to have a more flexible hose)
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Fuel sender clicked back in place
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Pump reassembled and ready to be dropped back in
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New pump in and waiting for steel hatch to be fitted
Reassemble the items in reverse order taking care not to pinch any wires around the hatch entrance.
Last edited by precopster on Sun Oct 12, 2014 2:38 am, edited 2 times in total.


Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI

www.precisioncarmodules.com.

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regent
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regent

Re: 2002 XC70 Fuel pump retrofit with P80 pump

Post by regent » Sat Oct 11, 2014 2:49 pm

Awesome writeup!
Thanks.


Example of Precision: Measure with a Micrometer, mark it with Chalk, and then cut it with an Axe.
Disclaimer: We (very) seldom do that

2015 BMW 335i
2015 XC60 T5 Premier Plus
2002 S60 2.4 n/a - retired :(
1987 340 DL - retired :(

precopster
Posts: 7423
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precopster

Re: 2002 XC70 Fuel pump retrofit with P80 pump

Post by precopster » Sat Oct 11, 2014 10:11 pm

Confession: this was actually done on my 2001 XC70 and I did the same thing on my 2002 XC70 yesterday.

A new revelation has surfaced as I discovered that the gauze filter separates from the plastic housing with some patient prying evenly around the edges. Hence no need for shopping bags :roll:

What I didn't expect the second time around was that the pump refused to be tapped out of the fixture.

I finally succeeded by levering it out by prying at the edges of the pump but it was a tough job.
Image


Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI

www.precisioncarmodules.com.

precopster
Posts: 7423
Joined: Sat Aug 21, 2010 12:20 am
Year and Model: Lots
Location: Melbourne Australia
Has thanked: 4 times
Been thanked: 94 times
Australia
precopster

Re: 2002 XC70 Fuel pump retrofit with P80 pump

Post by precopster » Sun Oct 26, 2014 7:17 pm

2 weeks and afew hundred kilometres from the fitment and no issues. The car used to ping before the fuel pump repair; no doubt caused by low fuel pressure. Some full acceleration bursts has clean power to the redline. Car gets by on far less throttle and fuel consumption is already less by 2L/100kms on short trips.

I researched some info regarding the OEM Bosch pump that was in the original fixture (0580453447) It is supposedly rated at 110L/hr and 3 bar pressure (around 43psi)

The P80 pumps provided by Bosch (0580314067) are rated at 120L/hr and are also 3 bar (43 psi) so this is effectively an upgrade though I believe the difference is negligible.


Current cars:2002 XC70, 2006 Ssangyong Rodius (Stavic), 2006 XC90 2.5T, VW Transporter 2.5TDI

www.precisioncarmodules.com.

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