fuel pump mod

[michael8888]

My original fuel pump died... but after 22 years and a 200,000 miles it was time.
The replacement was not a straight forward plug and play for my 98 V70T5m.
The replacement pump # 0580 314 067 I received from FCP is not a direct fit into the OEM housing assembly in my car. The original bosch pump # 0580 453 420 which has no plastic case around the metal pump. The good news is the replacement pump can be modified easily and the pump under the plastic cover is almost the same as the original.
The new pump has a nipple cast into the plastic cover which the filter is press fitted to. I decided to kept the intake plastic nipple part on the plastic housing, since I was not sure if the new or old filter would fit if I cut it out.
First, I cut away the housing with a 6” lenex mini hacksaw blade put in my jewelers saw and kept the cutting edge parallel to the side of the pump and slowly cut into the side of the housing. Next I cut a square around the nipple to separate it from the rest of the housing. You’ll only need to cut one side. Slide a 6”x1/4” blade screwdriver between the pump and the housing and the housing will crack off. You should be left with the nipple still intact. Next use the saw blade to trim the extra plastic off the nipple down to the brass ring. A foam ear plug squeezed into the intake might work to keep dirt out. File the plastic so it’s almost the nipple’s factory diameter where the filter presses onto. A Leatherman tool file will work, but I used my course jewelers file. Cut off about 5mm off the end of the nipple. FYI: be very careful not to let any dust or plastic filings go into the intake of the pump.
Wrap a piece of 320 sandpaper to clear up the edges. Sand very, very lightly or the filter will lose it’s ability to press fit onto the nipple and will fall off in the tank. If you over sanded and that happens, use some high quality teflon plumbers tape around the nipple. You should now be within 1-2mm of the original overall length. I have lots of photos if anyone needs them.
I’m guessing that Volvo used a few different housing bases on the complete pump assembly for different pumps and that the FCP’s replacement may be for a different assembly. Let’s also give a cheer to my wife for letting me do the work in the kitchen and getting that wonderful manly Eau de Octane (gasoline) Cologne on me.
see photos below.

[michael8888]

pumps side by side and aligned. new one in assembly. filters now about same distance from pump.

Nipple after clean up and cutting shorter

case after being cut off

new and old pumps side by side

[Clemens]

Nice writeup. I had a similar problem years ago, I can't remember how I solved it. Well done, thanks for sharing!