How to: Volvo 940 fuel filter replacement

[360beast]

I have done this on my 1997 940 with the single in tank fuel pump, the earlier cars had a second pump under the car next to the fuel filter. The method for changing the fuel filter will be very similar for the earlier cars.

First of all jack the car up on the rear N/S jacking point and out an axle stand under the car in a safe place. I put mine on a chassis crossmember so it acted as a handy mounting point for my lamp.

You then need to clamp off the fuel lines either side of the filter before removing anything to stop your fuel tank draining out on to the floor, I had run my 940 dry o I didn't have to.

Locate the hose fixings and undo them before anything else.


IMG-20200913-WA0002 by Luke Ryland - Flickr2BBcode LITE


IMG-20200913-WA0004 by Luke Ryland - Flickr2BBcode LITE

Next you need to undo the connections, there will be fuel in the filter that comes out, so you may want to have something ready to catch the fuel.


IMG-20200913-WA0009 by Luke Ryland - Flickr2BBcode LITE


IMG-20200913-WA0007 by Luke Ryland - Flickr2BBcode LITE

Now slacken off the 10mm bolt that holds the fuel filter in the strap but don't remove it fully.

Now undo the two 13mm filter carrier retaining bolts and one 13mm nut.

Now remove the 10mm bolt for the retaining strap. You can just slacken it and pull the filter out but I wanted to clean up the threads and grease the bolt.


IMG-20200913-WA0011 by Luke Ryland - Flickr2BBcode LITE

Now remove the union from the old filter and fit it to the new filter with a new copper washer. Don't forget two new washers for the banjo bolt.

Now you can refit it, when you refit it just put the filter back in the strap loosely, refit the carrier to the underside of the car and refit the lines and tighten them up, now you can tighten the strap up. This is to allow you to move the filter around to help fit the screw on hose on the back of the filter easier.

Hopefully that all makes sense.

[mhuk]

Not really relevant to maybe but that front banjo bolt is m12 1.5 pitch should you want to change from 6mm hose to 8mm banjo. Allows after market fuel regulator installs on 8m m

[360beast]

Originally Posted by mhuk

Not really relevant to maybe but that front banjo bolt is m12 1.5 pitch should you want to change from 6mm hose to 8mm banjo. Allows after market fuel regulator installs on 8m m

That's a handy bit of info!

[Laird Scooby]

Luke - i may have missed it but i don't see any mention of a backing spanner?

[360beast]

Originally Posted by Laird Scooby

Luke - i may have missed it but i don't see any mention of a backing spanner?

Backing spanner? Do you mean to remove the union from the old filter? If so then yes it was 27mm I think to hold the filter and 19mm on the union.

[Laird Scooby]

Originally Posted by 360beast

Backing spanner? Do you mean to remove the union from the old filter? If so then yes it was 27mm I think to hold the filter and 19mm on the union.

More about the use of one than the actual size really Luke. Those sort of unions should always have a backing spanner on the filter to prevent it rotating while the unions are undone to prevent the filter twisiting in the brack and doing other damage.
Damage can include the short pipe between the main pump and filter on older models which although is available from Volvo it's £50 and even from other sources such as BMW, Mercedes, Saab, VAG, Ford etc is still almost as pricey if they have them!

[taiwan740]

There's some jargon used here and in other guides that phases me.

Banjo bolt? Googled but can't visualise in this application
Union for the backing spanner?
How exactly do the filter ends undo? are they threaded on so its a socket on the end, or is it more like a hydraulic fitting, so you need two spanners?

Perhaps I'm being oblivious, but I'm young... 30 is still young...right? RIGHT?

[Laird Scooby]

Originally Posted by taiwan740

There's some jargon used here and in other guides that phases me.

Banjo bolt? Googled but can't visualise in this application
Union for the backing spanner?
How exactly do the filter ends undo? are they threaded on so its a socket on the end, or is it more like a hydraulic fitting, so you need two spanners?

Perhaps I'm being oblivious, but I'm young... 30 is still young...right? RIGHT?

You need two spanners, one of which is the backing psanner to hold the filter while you undo the banjo bolt (so named because it goes through a hydraulic banjo fitting) and the union is nothing to do with militant tendencies calling people out on strike, it's the union of two pipes, ideally a backing spanner should be used to prevent the vulnerable pipe twisting while the moveable part is undone.

Once again, Google is proved useless!

First results on the search engine i've used for donkeys :



https://en.wikipedia.org/wiki/Banjo_fitting

The filter ends have hex flats formed at manufacture to use a backing spanner on (you don't want the filter turning and damaging things behind it while you undo the banjo on the front and vice versa) and the banjo bolts hold the banjo fitting on with two crush washers (usually copper or aluminium, Saab use Dowty Washers instead and so do it) one either sdie of the banjo.
These crush washers provide the seal.

Think i've covered everything!

[mhuk]

Here is the banjo I used.

Only if you are going to for an aftermarket fuel regulator for example .
Volvo hose from filter into engine bay is a funny hose which is 6mm internal ID.

Not sure if it’s 6mm pre filter. I’m running a aem fuel pump.
And a billet fuel rail and performance fuel systems fuel regulator .
It’s tbh 8mm hose to adaptor an fittings. Works very well.

None of which is needed for a standard car.

[mhuk]

And the link https://www.ebay.co.uk/itm/281308192899