Removal, replacement and installation

WARNING: This page is about a different car, the 2001 Volvo S80, 2000 Volvo S80, and 1999 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Bumper Casing Front Bolts & Fasteners

Courtesy of VOLVO CARS OF NORTH AMERICA.

General extra information, in addition to that supplied in the installation kit, when installing the same.

Remove the bumper casing front for better access when replacing the heater in the next step.

Fig 2: Identifying Air Baffle & Splash Guard

Courtesy of VOLVO CARS OF NORTH AMERICA.

Remove the air baffle and the splash guard under the engine.

Fig 3: Identifying Fuel Lines

Courtesy of VOLVO CARS OF NORTH AMERICA.

Replace the suction pipe in the tank fitting with the one in the kit.

Tap it carefully into place so that it bottoms out against the sleeve.

Also replace the fuel line between the tank fitting and the rear fuel pump.

Press out both the old and new (which now is connected) fuel line above the tank so far to the right side as possible.

Fig 4: Identifying Fuel Tank & Hose

Courtesy of VOLVO CARS OF NORTH AMERICA.

Raise the car.

Lower the tank a little bit, which makes it easier to route the fuel hose from the tank fitting to the rear fuel pump.

9985972 with 9995972 under the fuel tank.

Loosen the tank strap screws on the right side.

Lower the tank but leave the jack in place underneath.

Fig 5: Identifying Fuel Line Routing

Courtesy of VOLVO CARS OF NORTH AMERICA.

Pull loose the old fuel line and discard it.

Route the new fuel line between the tank fitting and the fuel pump, leave the protective cap in place in the end of the fuel hose.

Route it along the tank on the right side, clamp it down as needed.

Fig 6: Identifying Sub-Frame Fuel Pipe & Fuel Heater

Courtesy of VOLVO CARS OF NORTH AMERICA.

Make sure to be thorough with the connection of the rear hose to the subframe pipe (1).

The insertion pipe must be used and adjusted so that it has contact against the corresponding part in the rear hose. Also, the subframe's pipe must have tight contact on the opposite side. Otherwise there may be problems with air leakage.

Install the new subframe fuel pipe in existing attachments (2).

Connection against the heater (3) and its fuel hose requires the same precision as in position 1.

After installing there is no need for test-driving or installing the bumper casing at this time. Install the installation kit, see supplied method description.

NOTE: Only remove the old fuel heater without modifying it.