Volvo Fuel Cell - New part # is different!

[Z275]

Need some help figuring out what the deal is with replacing the fuel cell on a 7.4GSI PEFS engine. According to Volvo the part number has changed to 3594444 which is what I ordered. Everything looked the same so I got it mounted but when I went to put on the high pressure hose on the HP pump I noticed the fitting on the pump was slightly different from the old pump. The old pump had a flange that came upwards on the pump connector that pressue fit to the hose fitting. The new pump has a flange going downward on the pump fitting which is the same design as the fuel return hose on the old and new pumps. The kind that requires an o-ring. I've attached photos of the old pump, new pump, and existing hose.
Does anyone know what's going on here? Is this not the right pump or does it require that I change over to a different high pressue hose? If so what is that part number?

Thanks for the help!

 

[Z275]

Re: Volvo Fuel Cell - New part # is different!

I forgot to mention the original pump was a 3860210.

 

[gatorgitter]

Re: Volvo Fuel Cell - New part # is different!

Hey, Z...

it might not help you too much, but I've got an '03 5.0 GXI-b engine, and one of the fuel pump whines a little , so I've checked out replacement fuel cells... from my notes...

My part is original part # is 3861355 , but everything says it's been replaced by 3594444 ( the same as your new one). I haven't taken mine apart yet, so I'm not sure about the fittings, but I'l be sore to refernce your pics when I do... Seems kinda strange that your big block and my small block would share the same fuel cell, imo ; but what the heck do i know ? ...

good luck, and let us know how you make out pls... There migt be a fuel pump in my future ; but, man, I sure hope not, as they're close to 600 bucks !

gator.

 

[Z275]

Re: Volvo Fuel Cell - New part # is different!

ok, got it figured out now Even though the service manual says never allow the fitting on the high pressure pump to twist, you do just that. Put a wrench around the brass valve coming out the top of the HP pump and then loosen the large brass fitting with another wrench. It will unthread and you'll see a o-ring at the end of the threads. This o-ring is part # 3850423. Now remove the fitting from the new pump in the same fashion and tighten the new one down to 17ft/lbs. You will also want to order o-ring #3850424 which is the one that goes on the fuel return line. You don't need to change fittings on this line though.
All the brass fuel fittings should be tightened to 17ft/lbs. You'll probably need a crowfoot wrench to do this on the hose fittings.
I would also recommend using a thread sealer on the connection between the high pressure feed hose and the fitting on the high perssure pump. Permatex makes several types of gasket maker and thread sealer that are safe for gas applications. A mechanic told me he always has used teflon tape although I don't think the mfg specifically rates it for use on fuel connections.