- Edited
There are plenty of guides online for this but I found them all lacking for the 7 seat version. One even suggests removing the 3rd row seats, another shortcuts this by cutting the carpet (!). Volvo says leave it in place and fold it out of the way.
The best tutorial is here volvoforums.com/forum/volvo-xc90-9/xc90-fuel-pump-replacement-tutorial-70880/
There's a 2003-2005MY recall in the US with the Volvo replacement instructions here www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/ACM14888311/RCMN-09V483-9234.pdf
However; these pumps were specifically designed for duty in the southern hemisphere (where liquids go down the drain the right way), these pumps only fail in the US, hence the recall there. Apparently my XC90 has spent time in the US as it has failed in the same manner as described in the recall notice for the US. Avoidance of liability by Volvo Oz or ACCC asleep again? Surely not B).
Access to the pump is poor with the carpet in place and it all needs to be cleaned to prevent dirt entering the tank.
To improve access, I removed the rear floor carpet without removing the third row of seats. It needed a thorough clean back there anyway. To do this, after removing the trims to access the frame:
(Updated)
1 - remove the front row of bolts (3 off) 1 under each seat and 1 in the centre (visible in photo below)
2 - lower rear seats. There are two bolts each side (4 total) at the rear of the frame which are just accessible with a socket if you deform the trim slightly (i.e. it is not necessary to remove the side trims in the load area if you do this). Loosen these.
3 - Loosen the 4 bolts in the centre (visible in photo below)
4 - raise seat backs
5 - lift the front of the frame (note short extension bar in photo below - the photo is taken at this point)
6 - remove carpet forwards
This added about 30 min to the whole job. Volvo Service Bulletin says 2.3 hours. I'd suggest you allow 4 for the first time with cleaning.
FCP Euro delivered the pump in 5 days (thanks Philia bear). BOSCH OEM - check your VIN chassis number.
Also order the removal tool or be prepared to invest time in manufacturing one out of a 100 DWV socket and more time making it work in the confined space.
The best tutorial is here volvoforums.com/forum/volvo-xc90-9/xc90-fuel-pump-replacement-tutorial-70880/
There's a 2003-2005MY recall in the US with the Volvo replacement instructions here www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/ACM14888311/RCMN-09V483-9234.pdf
However; these pumps were specifically designed for duty in the southern hemisphere (where liquids go down the drain the right way), these pumps only fail in the US, hence the recall there. Apparently my XC90 has spent time in the US as it has failed in the same manner as described in the recall notice for the US. Avoidance of liability by Volvo Oz or ACCC asleep again? Surely not B).
Access to the pump is poor with the carpet in place and it all needs to be cleaned to prevent dirt entering the tank.
To improve access, I removed the rear floor carpet without removing the third row of seats. It needed a thorough clean back there anyway. To do this, after removing the trims to access the frame:
(Updated)
1 - remove the front row of bolts (3 off) 1 under each seat and 1 in the centre (visible in photo below)
2 - lower rear seats. There are two bolts each side (4 total) at the rear of the frame which are just accessible with a socket if you deform the trim slightly (i.e. it is not necessary to remove the side trims in the load area if you do this). Loosen these.
3 - Loosen the 4 bolts in the centre (visible in photo below)
4 - raise seat backs
5 - lift the front of the frame (note short extension bar in photo below - the photo is taken at this point)
6 - remove carpet forwards
This added about 30 min to the whole job. Volvo Service Bulletin says 2.3 hours. I'd suggest you allow 4 for the first time with cleaning.
FCP Euro delivered the pump in 5 days (thanks Philia bear). BOSCH OEM - check your VIN chassis number.
Also order the removal tool or be prepared to invest time in manufacturing one out of a 100 DWV socket and more time making it work in the confined space.
