Fuel tank, replacing: Removal

Fuel system, draining 

To drain the fuel from the system, see Draining the fuel system

Draining the tank 

If the fuel tank is more than half full, drain the fuel tank. See Draining the fuel tank

In the passenger compartment 

Remove 

• the backrest. See The backrest

Fig 1: Identifying Pushing Carpet Aside And Locating Level Sensor/Fuel Pump Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• the insulation panel.

Fig 2: Identifying Fuel Level Sensors Covers, Connectors And Nuts

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Remove the covers over the fuel level sensors
• Disconnect the 2 connectors on the left and 2-3 on the right-hand side. Let them follow the fuel tank down.

Exhaust pipe, rear section 

Fig 3: Identifying Exhaust System, Brackets And Fasteners

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the car

Remove 

• the rear section of the exhaust pipe. Support the front section of the exhaust pipe so as not to put strain on the exhaust manifold.

Heat deflector plate 

• Remove the left rear wheel
• Remove the rear plastic nut from the plastic fender liner.

Fig 4: Drilling Out Heat Deflector Plate Rivet On Sub-Frame Left Rear Bushing

Courtesy of VOLVO CARS OF NORTH AMERICA.

• Drill out the two blind rivets holding the heat deflector plate at the rear sub-frame mounting and the third rivet on the rear bracket for the exhaust system. Use a 5 mm drill bit
• Remove the plastic nuts and the heat deflector plate.

Exposing the fuel tank 

Fig 5: Identifying Hose Clamp On Carbon Filter

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove 

• the plastic pipe with the largest connection to the carbon filter container by pressing towards the container, pressing the two catches and pulling off. Position the pipe forwards towards the fuel tank
• the plastic pipe between the canister purge (CP) valve and the carbon filter container from the clip on the fuel tank
• the ABS wiring from the fuel tank
• the bracket for the fuel filter
• the brake cable from the left rear brake. See Replacing brake cables
• the screws from the heat shield at the front of the fuel tank. Position the brake cables in front of the heat shield
• the hose clamps, fuel filler pipe and the shut-off pipe at the fuel tank.

Tank, lowering 

Fig 6: Identifying Transmission Jack With Fixture (999 5972) Positioned Under Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Apply the transmission jack with fixture 9995972 under the tank.

Remove 

• the tank retaining straps and lower the tank slightly
• the hoses from the tank unit.

Check that the lines and wiring are unimpeded during the rest of the lowering.

Draining fuel tank 

Drain the fuel from the fuel tank. See Draining the fuel tank .

Transferring components 

Transfer 

• the right-hand level sensor and pump. See: Replacing the right-hand level sensor and pump
• the left-hand level sensor. See: Level sensor, fuel tank, left, replacing
• the fuel tank pressure sensor. See: Pressure sensor, fuel tank, replacing  (certain markets only)
• the hoses for the fuel filler pipe and breather pipe
• the fuel filler extension in the fuel tank
• the heat shield under the fuel tank
• the clip for the brake cable
• the tank straps.