Fuel tank, replacing: Installation

Fuel tank 

Fig 1: Identifying Transmission Jack With Fixture (999 5972) Positioned Under Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Lift up the fuel tank.
• Install the hoses on the fuel tank unit. Ensure that no lines or wiring are trapped
• Position the wiring to be routed into the passenger compartment uppermost
• Install the fuel filler pipe and the bleed pipe. Use new screw clips
  NOTE:

  Install the screw clips so that they can be easily tightened.

• Tighten the screws for the tank retaining strap. Tighten to 25 Nm 
• Remove the mobile jack

Install 

• the fuel filter with the bracket Tighten to 25 Nm 
• The ABS wiring in the clips on the fuel tank
• the brake cables behind the heat shield at the front edge of the fuel tank and in the clips. Screw the heat shield into place
• the brake cable at the left rear brake. See Replacing brake cables
• the plastic pipe between the canister purge (CP) valve and the carbon filter container in the clip on the fuel tank
• the plastic pipe with the largest connection to the carbon filter container. A "click" must be heard.

Heat deflector plate 

Fig 2: Identifying Fender Liner Installation Using Plastic Nut

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Position the heat deflector plate and install the plastic nuts
• Install the pop rivets, one at the bracket for the exhaust system and two on the rear mounting for the sub-frame
• Install the left rear wheel.

The rear section of the exhaust pipe 

Fig 3: Identifying Exhaust System, Brackets And Fasteners

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Install the exhaust system. Tighten the screws. Tighten to 25 Nm  .

The passenger compartment 

Fig 4: Identifying Fuel Level Sensors Covers, Connectors And Nuts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install 

• The 2-3 connectors on the right and the 2 connectors on the left
• the covers over the level sensors. Check that the gasket is correctly positioned
• the insulation panel
• the backrest. See The backrest .