Replacing fuel tank pressure sensor

Special tools:

Preparations

Fig 1: Identifying Cargo Compartment Carpet And Cover Over Fuel Pump (FP) Unit

Courtesy of VOLVO CARS OF NORTH AMERICA.

5-door cars:

4-door cars:

Disconnect connectors

Fig 2: Identifying Connectors And Cables At Fuel Pump

Courtesy of VOLVO CARS OF NORTH AMERICA.

Disconnect all connectors on the bracket.
Remove rubber bracket around wiring.
Remove fuel filler pipe ground lead from nut on fuel tank level sensor cover.
Ensure that all cables routed through the fuel pump (FP) unit hole are free to follow the fuel tank when it is lowered.

Fig 3: Identifying Fuel Filler Pipe Ground Lead

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove fuel filler pipe

Fig 4: Identifying Rubber Seal

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove fuel tank

Fig 5: Identifying Mobile Jack With Fixture

Courtesy of VOLVO CARS OF NORTH AMERICA.

Position mobile jack with fixture 9995972 under fuel tank, check that the lifting platform is flat so as not to damage the fuel tank.
Undo tank retaining straps and lower tank slightly.

Remove front holder

Fig 6: Identifying Hoses

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the entire mounting from the bracket by pulling it towards the right of the car.
Disconnect the hose between the EVAP canister shut-off valve and air cleaner (ACL) from the clamp on the fuel tank.
HINT: Note position of hose in the clamp in case it opens. The hoses must be reinstalled in their original positions.

Replacing fuel tank pressure sensor

Fig 7: Fuel Tank Pressure Sensor

Courtesy of VOLVO CARS OF NORTH AMERICA.

Fig 8: Identifying Clamp Being Squeezed By Pipe Wrench

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the screw
Removing clamp:
- squeeze clamp with a pipe wrench. Hold in place
- pry apart with a small screwdriver.
  NOTE:
  It is reusable.
Remove clamp
NOTE:
The clamp will be reused

Removing clamp:
- squeeze clamp with a pipe wrench. Hold in place
- pry apart with a small screwdriver.
  NOTE:
  It is reusable.
Disconnect hose.
Installing clamp:
- Press in the clamp with a pipe wrench until it locks.
Remove cable harness.
Installing clamp:
- Press in the clamp with a pipe wrench until it locks.
Install the new pressure sensor, route cabling as before.
Installing clamp:
- Press in the clamp with a pipe wrench until it locks.

Installing fuel tank

Fig 9: Identifying Front Holder, Bracket And Fuel Pump Unit Hole

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the fuel tank so that the front holder can be installed to the bracket by pressing it until it locks into place.
Ensure that cabling routed through the fuel pump (FP) unit hole will not be trapped when the fuel tank is installed.
Raise the fuel tank and fix it to the bodywork.
Install EVAP canister shut-off valve hose in the clamp on the fuel tank.

Installing rubber cover on fuel filler pipe

Fig 10: Identifying Circlips, Rubber Cover Sealing Surface And Drain Pipe

Courtesy of VOLVO CARS OF NORTH AMERICA.

Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
Check that circlip (1) is in position.
Lubricate rubber cover sealing surfaces (2) with petroleum jelly.
Install rubber cover (ensure that it is correctly positioned in relation to bodywork).
Install circlip (4) and drain pipe (3).
Connect all connectors and install fuel filler pipe ground lead.
Install rubber bracket around wiring.
Install panels, covers and carpets.