Changing the fuel tank

WARNING: This page is about a different car, the 2002 Volvo C70, 2001 Volvo C70, 2000 Volvo C70, 1999 Volvo C70, and 1998 Volvo C70. However, it is still accessible from the selected car via links, so may be relevant.

Removing the tank pressure sensor (certain markets only)

Cut off the cable tie from around the cable harness.
Bend aside the cable harness.
Remove the bolt and twist out the bracket and tank pressure sensor.
Remove the fuel line holder from the tank pressure sensor.
Remove the tank pressure sensor.

Transferring to the new fuel tank

Change the fuel tank with a new one.

Transfer:

Filler pipe
Heat shield

Fitting the tank pressure sensor (certain markets only)

Fit the fuel line and holder.
Fit the tank pressure sensor.
Twist the bracket back into position and screw into place.
Return the cable harness to its original position.
Secure the cable harness with a cable tie.

Fitting the fuel pump units

Fig 1: Identifying Pump Unit And Special Tool 9995673

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the fuel pump units

Install:

new gaskets
the LH pump unit
the RH pump unit.

Grease all contact surfaces of the pump units' retaining nuts with Vaseline.

NOTE: Do not apply Vaseline to the nut threads.

Tighten the nuts with 40 Nm . Use special tool 9995673 as a counterhold. The tool's indicator tip must be between the markings on the fuel tank in order for the placement of the pump units to be correct.

NOTE: Make sure the pump units are correctly positioned so that the fuel gauge shows the correct value.

Fitting the rear suspension assembly

Fig 2: Fuel Lines Secured To Mountings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the fuel lines

Position and secure the fuel lines to their mountings in the same order as they were removed.

Fig 3: Removing Fuel Line From Fuel Pump

Courtesy of VOLVO CARS OF NORTH AMERICA.

Install:

the fuel line attachments between the fuel pump and fuel filter
the fuel lines from the fuel pump and ejector pump.

Fig 4: Fuel Lines Secured To Mountings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the fuel lines into the clips

Fit the return line from the ejector pump (LH side).

Fig 5: Identifying Pop Rivet And Cable Tie At Jack Attachment/Longitudinal Stay Brackets

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Fitting the handbrake cable

Raise the rear suspension about 10 cm.

Remove the cable tie (A).

Fit the handbrake cable with clips; use a pop rivet (ø 4 mm) (B).

Fig 6: Lowering Rear Suspension And Fuel Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raising the rear suspension

Raise the rear suspension with fuel tank.

Make sure the filler pipe does not foul the wheel arch liner. Make sure the fuel line is clear of the body and that the fuel gauge line does not get caught in the fuel strap brackets.

Lift up the tank fitting lines and fuel pump lines through the body (hatch).

CAUTION: Secure the front part of the differential to the lift table. This prevents the rear suspension from tipping backward when lifted.

NOTE: Check also that the fuel line between the fuel level sensor and the ejector pump does not foul the body when the rear suspension is lifted.

Adjust and secure the filler pipe's crash guard bracket.

Fig 7: Identifying Rear Axle Member Guide Holes And Rear Retaining Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the retaining bolts for the rear axle member

Apply a couple of drops of threadlock, part number 1161351-0, to each bolt.

Fit all the retaining bolts for the rear axle member.

NOTE: Before fitting the rear axle to the body, measure the distance between the rear axle member guideø 16.5 mm holes (A) outside the rear retaining bolts, and theø 16 mm holes furthest to the rear on the side members. The distance between the holes should be 595 mm +/- 2 mm.

Tighten the outer bolts to 80 Nm and the center bolts to 50 Nm .

Fig 8: Identifying Tank Strap Bolt

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tightening the tank strap attachments

Tighten the tank strap attachments on both sides.

Remove the lift table.

Fig 9: Identifying Fuel Lines, Plastic Clip, And Protective Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the fuel tank EVAP lines

Install:

the brake pipe in the 4 clips
the fuel and EVAP lines
the lines to the protective cover
the protective cover, use new nuts and washers
protective covers.

Fig 10: Identifying Propeller Shaft And Special Tool (Holder) 9995561

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the propeller shaft and driver

Fit the propeller shaft to the driver.

NOTE: Fit the propeller shaft as marked earlier. Refit the bolts in their original positions.

Check that the contact surfaces of the viscous coupling and propeller shaft driver are clean.

Tighten opposite bolts to 8 Nm . Then tighten opposite bolts to 30 Nm . Use holder 9995561 . Start by tightening the same bolt both times.

Fig 11: Identifying Link Arms And Tensioner 999 5659

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Fitting the longitudinal stay mountings and jack attachments

Fit the front longitudinal stay mountings and the jack attachments to the body.

Press up the link arms to their normal position.

See tension yoke and normal position.

Connect the LH three-way branching to the LH jack attachment.

Fit the longitudinal stay brackets and the jack attachments using new bolts.

Tighten the 3 bolts for the longitudinal stay bracket to 65 Nm + 60° .

Tighten the bolt through the jack attachment to 105 Nm + 90° .

Fig 12: Identifying Rear Exhaust Pipe

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Fitting the exhaust pipe

Install:

the rear exhaust pipe
the silencers.

NOTE: Check that there is clearance to the heat shields.

Fig 13: Identifying Filler Pipe

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Fitting the filler pipe

Fit the fuel filler pipe to the body with the rubber bellows and lock ring.

Fig 14: Identifying Front Cover And Connectors For ABS Sensor And Fuel Level Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the hatches and connections to the tank fitting

Install:

the front and rear hatch in the body and the connector holder. Make sure the rubber seal around the wiring is properly fitted when the rear hatch is fitted.
the connectors to the tank fitting, fuel pump and ABS system.

Fig 15: Identifying Fasteners On Cargo Compartment Floor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Positioning the luggage compartment floor mountings

Position:

the mounting at front edge of the luggage compartment floor. Fit the screws along the rear edge.
the hatch with the rear floor hatch.

Tighten the bolts.

Fig 16: Identifying Wheel Arch Liner And Mudflap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fitting the rear wheels

Install:

the wheel arch liner and mud flap on rear edge on right-hand side.
the rear wheels.

Refill the fuel tank.

Test drive and perform functional checks.