IPD sale XeMODeX - Experts in Volvo Electronics
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy your stuff using this and it helps MVS!

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
Posts: 7459
Joined: Sat Aug 21, 2010 12:20 am
Year and Model: Lots
Location: Melbourne Australia
Has thanked: 4 times
Been thanked: 102 times
Australia
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
20141010_104634 (Large).jpg
20141010_111412 (Large).jpg
20141010_111426 (Large).jpg
20141010_111429 (Large).jpg
20141010_111553 (Large).jpg
20141010_112128 (Large).jpg
20141010_112428 (Large).jpg
20141010_112545 (Large).jpg
20141010_112724 (Large).jpg
20141010_112912 (Large).jpg
20141010_113520 (Large).jpg
20141010_113650 (Large).jpg
20141010_114259 (Large).jpg
20141010_113901 (Large).jpg
20141010_114340 (Large).jpg
20141010_120051 (Large).jpg
20141010_120445 (Large).jpg
20141010_120602 (Large).jpg
20141010_120620 (Large).jpg
20141010_120612 (Large).jpg
20141010_120743 (Large).jpg
20141010_121835 (Large).jpg
20141010_122431 (Large).jpg
20141010_123643 (Large).jpg
20141010_144934 (Large).jpg
20141010_145004 (Large).jpg
20141010_180445 (Large).jpg
20141010_180939.jpg
20141010_181219.jpg
20141010_181336.jpg
20141010_181405.jpg
20141010_181517.jpg
20141010_182554.jpg
20141010_184226.jpg
Reassemble the items in reverse order taking care not to pinch any wires around the hatch entrance.
You do not have the required permissions to view the files attached to this post.
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.

User avatar
regent
Posts: 1247
Joined: Mon Feb 22, 2010 6:34 pm
Year and Model: 2015 XC60 T5
Location: Under the Hood
Has thanked: 1 time
Been thanked: 5 times
United States of America
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: 7459
Joined: Sat Aug 21, 2010 12:20 am
Year and Model: Lots
Location: Melbourne Australia
Has thanked: 4 times
Been thanked: 102 times
Australia
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: 7459
Joined: Sat Aug 21, 2010 12:20 am
Year and Model: Lots
Location: Melbourne Australia
Has thanked: 4 times
Been thanked: 102 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.

Post Reply