Fuel tank, replacing: Notes

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.

Special tools:

9812270

9812273

Safety

First see Safety regulations for handling fuel .

Preparation

Draining the fuel tank

To drain the fuel tank, see Draining the fuel tank AWD and 2WD/ORVR

If you have drained the fuel tank according to the "non working fuel pump" method continue according to Changing the fuel tank .

Draining the fuel system

To drain the fuel system, see Draining fuel injection system .

Fig 1: Identifying Fasteners On Cargo Compartment Floor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the cargo compartment floor

Remove the front and rear cargo compartment floor.

Fig 2: Identifying Front Cover And Connectors For ABS Sensor And Fuel Level Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Unplugging connectors

Unplug the connectors of the ABS sensor and fuel gauge.

Remove the connector holder and the front cover.

Feed the lines through the hole.

Fig 3: Identifying Filler Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the filler pipe

Remove the lock ring of the rubber bellows.

Press in the rubber bellows with the filler pipe into the wheel housing.

Fig 4: Identifying Wheel Arch Liner And Mudflap

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the rear wheel

Remove:

the rear wheel
the wheel arch liner and mud flap of the RH wheel housing.

Fig 5: Identifying Fuel Lines, Plastic Clip, And Protective Cover

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnecting the EVAP lines of the fuel tank

Remove the protective cover from the fuel lines.

Removing the protective covers from the fuel tank

Remove:

the protective covers along the front edge of the fuel tank (3 plastic nuts on each cover)
all pipes from the plastic clips on the fuel tank.

Fig 6: Identifying Rear Exhaust Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the exhaust pipe

Remove the rear exhaust pipe and silencers.

Fig 7: Positioning Engine Lift Against Longitudinal Stay Mounting

Courtesy of VOLVO CARS OF NORTH AMERICA.

Detaching the longitudinal stay mountings

Detach the longitudinal stay mountings from the body.

Position an engine lift gently against the longitudinal stay mounting.

Remove:

the bolts for the jack attachment and longitudinal stay mounting in the body, both sides
the engine lift.

Undo:

three-way branching on LH jack attachment.
the front brake pipe from the 4 clips under the car.

Fig 8: Identifying Pop Rivet And Cable Tie At Jack Attachment/Longitudinal Stay Brackets

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the handbrake cable

Remove the handbrake cable from the jack attachment by drilling out the pop rivet (B).

Tie the jack attachment to the longitudinal stay brackets (A). Use a cable tie.

Fig 9: Identifying Propeller Shaft Bolts

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the propeller shaft

Mark the propeller shaft in relation to the driver.

NOTE: Note the bolt length and location on the CV joint. See the table below (standard bolts for front and rear CV joints and balancing bolts for rear joint).

Remove the propeller shaft bolts. Use holding tool 9995561 . Move the shaft to one side.

Standard bolts for front and rear universal joint and balancing bolts for rear joint

NOTE: Before removing the propeller shaft from the companion flange: Carefully mark the position of the propeller shaft in relation to the companion flange. Check also whether balancer bolts are fitted. Where applicable, note the position and length of the balancer bolts.

Standard bolts	length 50 mm	red marking (lock paint)
Balancing bolts	length 52.5 mm	white marking (lock paint)
Balancing bolts	length 55 mm	blue marking (lock paint)
Balancing bolts	length 57.5 mm	black marking (lock paint)
Balancing bolts	length 60 mm	yellow marking (lock paint)
Balancing bolts	length 62.5 mm	grey marking (lock paint)
Balancing bolts	length 65 mm	green marking (lock paint)
Balancing bolts	length 70 mm	red marking (lock paint)

NOTE: If the previous propeller shaft is refitted without replacement of the rear joint or removal or replacement of the companion flange on the differential, perform the following: fit the propeller shaft using the markings made upon removal. Use new bolts of the same length as those removed. If the propeller shaft is to be changed, the new shaft must be fitted with new bolts of standard length.

Fig 10: Positioning Jack Against Torque Tube

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lowering the torque tube

Position the jack 9985972 against the torque tube.

Remove the bolt and lower the torque tube with the engine lift.

Removing the rear suspension assembly

Fig 11: Positioning Lifting Table With Fixture Under Tank And Link Arms

Courtesy of VOLVO CARS OF NORTH AMERICA.

Positioning the lift table

Place the lift table with fixture under the tank and link arms.

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

Fig 12: Identifying Tank Strap Bolt

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the tank strap bolts

Remove the tank strap bolts from both sides.

Fig 13: Identifying Bolts Securing Rear Axle Member To Body

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the rear axle member bolts

Remove the bolts securing the rear axle member to the body on both sides.

Fig 14: Lowering Rear Suspension And Fuel Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

Lowering the rear suspension with fuel tank

Carefully lower the rear suspension and fuel tank about 30 cm.

Check that the fuel filler pipe is clear of the wheel arch liner.

NOTE: Check also that the fuel line between the fuel level sensor and the ejector pump does not foul the body during lowering.

NOTE: Check that the brake pipes are clear.

Fig 15: Fuel Lines Secured To Mountings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing fuel lines

CAUTION: Note the position of the fuel lines on the tank so that they are given corresponding positions on the new tank.

Unhook the fuel lines from their mountings.

CAUTION: Plug the disconnected fuel line fittings with part number 1203219-9 (door button 200/700/900) to prevent fuel spills.

Fig 16: Removing Fuel Line From Fuel Pump

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing fuel line fittings

Remove:

the fuel lines from the fuel pump and ejector pump, use special tool 9995666
the fuel line attachments between the fuel pump and fuel filter.

NOTE: Do not remove the fuel line between the fuel pump and the ejector pump.

Fig 17: Fuel Lines Secured To Mountings

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the fuel lines from the clips

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

Fig 18: Identifying Pump Unit And Special Tool 9995485

Courtesy of VOLVO CARS OF NORTH AMERICA.

Removing the pump units

Remove:

the pump unit on the left-hand side
pump unit on right-hand side. Use special tool 9995485 .