Thanks Luketrash for your write-up on going to the salvage yard to get a fuel pump out of a 850 wagon. This would apply to wagons up through ’00 as well:
Perhaps this will help someone else faced with fuel pump removal.
I purchased a pick’n’pull fuel pump out of a 138k Volvo 850 turbo today at my local salvage yard.
It didn’t take me very long to get it out once I thought about what tools I had on hand.
Here’s sort of a step by step, if anyone wants to write up a how-to.
Find your fuel pump access panel. I have a wagon, so it was under the inner flip-up panel in the hatch. Remove the 5 10mm nuts and use a flathead screwdriver to pry up the panel.
Pull the wiring harnesses free from their mounting point on the car (there’s all sorts of wires hooked up back there.)
* Depressurize your fuel system up under the hood next to the throttle pulley by unscrewing the cap on the schrader valve on the fuel rail. Blow the gas into a rag or something. No smoking!
Ok, back in the fuel pumpish area:
I found it very easy to use my spark plug boot pliers to pull the fuel lines free from the top of the pump. No risk of breaking things by using flathead screwdrivers.
Next, I used Jigaloo (use your silicone lubricant of choice) sprayed around the neck of the black retaining ring that holds the fuel pump onto the gas tank. I used it up by the top of the fuel pump as well as down around the bottom.
Then, since the retaining ring wasn’t budging by me using a mallet and screwdriver as a drift, I remembered my oil filter pliers. They worked very well to break it free and subsequently loosen the retaining ring:
Push all the little tubings and wires out of the way once you pull the retaining ring free and slowly pull out your fuel pump. If you’re like me, you have just filled your gas tank full right before doing this:
Out with the old, in with the new. Installation is the reverse of removal (don’t you hate it when you read that sentence???)
While I was putting away my tools, I noticed that my Austin Healey was trying to sneak into the hatch of my wagon….
The whole process took me less than a half hour including thinking about how to do the job as easy as possible.