Cable routing when replacing the fuel tank

Fig 1: Fuel Lines And Electrical Wiring Routing In Tank

Courtesy of VOLVO CARS OF NORTH AMERICA.

If replacing the fuel tank, wire cannot be used.

The image shows how to route the fuel lines and electrical wiring in the tank. Use a plastic pipe at least 1.7 m long.

HINT: Use spare part plastic pipe between the carbon filter and EVAP valve. 

Insert the hose through the hole for the level sensor on the left-hand side of the vehicle and press it through the tank and take the end of the hose through the hole for the fuel pump.

Fig 2: Fuel Lines/Electrical Wiring Taped To The Plastic Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Tape the fuel pump's fuel lines/electrical wiring to the plastic pipe.

Pull the wiring out of the hole for the level sensor. Remove the plastic pipe and the tape. Check that there is no tape/adhesive residue on the wiring.

Pull the wiring forwards and backwards to check that it has not bent or got trapped.