Where to cut? Fuel pump help for AWD car

[FlyingVolvo]

Hi all,

So, in light of my fuel pump check valve committing suicide, and my now definite drive to Alaska and back in a month, I've decided it wouldn't be a bad idea to just replace the whole fuel pump assembly.

As you know, for an AWD XC, fuel pump removal typically involves dropping the tank, something I have NO intention of doing. I've seen threads where people have had success in cutting an access panel. Unfortunately, none of these pictures have any point of reference, and they're all zoomed in...

Can somebody PLEASE post a good picture of exactly where to cut this opening?

Thank you much!

PS. Related question. What's the difference between the "fuel pump insert", "fuel pump assembly", and "fuel pump sending unit"? Which ones has the check valve? And is the sending unit JUST the thing that tells you how much gas you have left?

[FlyingVolvo]

Called up a forum member who's done this and I got it all figured out. Expect a detailed write-up sometime in the next few weeks!

[BEJinFbk]

definite drive to Alaska and back in a month

Sounds fun. It's an AWEsome trip!
Get yourself a "Milepost" travel guide for the Alcan.
Deal with the extra miles and avoid the Cassiar.
Schedule a stop at Laird Hot Springs.
Don't forget your passport!

Oh, yeah - Check this:
http://volvospeed.com/vs_forum/topic/14 ... d-install/

[anodyne]

The PO of my car did this exact same thing and I didn't see it when I bought the car. If I had, I wouldn't have bought it. You will compromise the floorboard integrity for sure. I sit my kids in the backseat and I don't like it much. The bottom front edge of the rear seats rest on your cut points and it also increases road noise. For the time being I have put duct tape on the edges to deaden noise. I want to have it welded secure. Just my experience.

[jblackburn]

Gives you an excuse to buy a welder, Ed! I've always wanted one. I took a welding class in high school just for the heck of it and loved it.

[MilwaukeeV70owner]

Not sure this will help, but here's what I had to do when I replaced the pump and fuel pressure regulator. I dropped the tank and it might give you some ideas of where to cut since I believe we have the same make/model.

https://www.matthewsvolvosite.com/forums ... =1&t=32192

[gilhuly]

I did one of these about 6 wks ago. The cut is in the diagonal/vertical wall of the floor pan yhat would be behind your heels if you were seated in the back seat. Start the cut on the left side (center) of the floor pan where it contours for the driveshaft and cut near, not to the top of the panel as well. The whole cut is probably8 or 9 " high and 6-7" wide.

Honestly, if I didn't know I had a bad fuel pump or something compromised on top of the pump I'd stay away from this job.

[Xilikon]

I could take pictures with a good point of reference where I cut out mine (it was a bit narrow but just enough to get access to the fuel pump). I need to access again since my last attempt to reseal it reusing the same lock ring and gasked failed even if it seems to improve a bit. I have the new ring and gasket on hand, waiting for a sunny day to do it.

LMK if you need it.

P.S. : If I need to unplug the fuel pump, where is the connector placed ? The wire was going under the back seat up to either access traps.