Fuel tank, replacing: Preparation

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.

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 Fuel 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 hand brake cable

Remove the hand brake 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 chart 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.