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Replacing the Fuel Pump/Sender Unit

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Old Sep 22nd, 2012, 22:12   #11
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I had the same.... non working fuel gauge. After a quick read on this, the job was done and dusted in about 30 mins...

Fuel gauge now working

Thanks Chaps
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Old Sep 22nd, 2012, 22:29   #12
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Glad I could help
Current car: 2002 S40 1.9D, 1992 240SE project
Previous Volvos: 1999 S40 1.8, 2001 S40 T4

Click here for my S40/V40 Info and Guides
Nullius in Verba
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Old Jan 21st, 2013, 19:59   #13
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Originally Posted by mechakev View Post
Great guide, may I add a tip?
Check the condition of the cables from the fuel reading potentiometer and the top of the pump. The up and down motion can cause the cable to break. A multimeter is great for checking this kind of stuff out. A quick solder fixed mine (my gauge was showing empty).
This fix definitely worked for me, great guide and was the wire as mechakev says I now have a fully working gauge
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Old Feb 13th, 2013, 20:39   #14
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Hi as any one got a guide to the wiring of the fuel pump/sender unit
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Old Feb 14th, 2013, 04:28   #15
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fantastic how to guide gatos as always. this is a great help my guage works OK ish it just doesn't read full when it is full its a mark or 2 off, so when the weather gets better!!!! i will sort it out.
2013 V40 D3 manual, standard
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Old Jun 9th, 2013, 20:26   #16
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Talking Great walkthrough Gatos!!!!

I Love this instruction. I drove about three months with the needle of my fuelmeter on zero. I hated this. My volvogarage repared this problem three times and still after one year the problem came back. I never heard a clear explanation from the garage about the cause. Now I know. In my case TWO wires were broken.
Watch out when you solder, the plastic housing tends to melt when you heat the connector where the wire fits in.

Thankyou Thankyou Thankyou!!!!!!!!!!
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Old Dec 6th, 2013, 04:10   #17
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Thank you Gatos for the excellent write up!

Last edited by zealerz; Dec 6th, 2013 at 04:15.
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Old Mar 6th, 2014, 17:09   #18

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Finally got round to having a look at mine. Broken wire so soldered and it's working again. Quick tip from me is to have some baby wipes present at all times and have a good clean as you go. A stiff rag or cover of some sort is handy when the unit is out of the car and the tank is exposed to cover it from pesky flies or accidental debris getting into the tank.
Its also 100% easier to put the rubber seal in first when refitting the sender unit.
Thanks for the guide Gatos, big thumbs up from me.
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Old Mar 6th, 2014, 17:52   #19

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Another thing I noticed is that after disconnecting the battery the mileage trip info on the dash and info center display went back to zero. Might be worthwhile making a note of your details beforehand just in case you have a problem and have to replace a faulty unit.
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Old Mar 20th, 2014, 16:01   #20
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I am new to the forum and to volvos

I recently got a 2010 volvo c30 1.6D and the fuel gauge has never worked correctly on it. it drops to half a tank very soon after filling.

I took it to volvo here (v expensive) and they hooked it up to VIDA and showed no errors so must be similar problem as this one.

I have it booked into my mechanic to try and solve it this saturday. Do i need to get a new seal for it? anything else i should know.

Really hoping it is something simple as I'm broke and volvo quoted 300 put new sender unit in and may not even need it. They just told me computer works.....

thanks in advance
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