Replacing fuel tank. Copyright 2004 Volvo Car Corporation. All rights reserved. Draining fuel tank

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1 "VCC EN " 1(6) Replacing fuel tank Special tools: , , , , , , Draining fuel tank Use draining unit , 2273 and Insert hose in filler pipe. Note! Insert hose at least 1 meter in order to reach the fuel. Cut the end of hose at an angle to get past all sharp edges. Removing panels 5door cars: Fold up the front floor hatch and fold back carpet. 4door cars: Fold forward right rear seat Remove: Cargo compartment carpet. Right wheel arch panel. Fold back the corner of panel on variants with soft panels. Covers over nuts to fuel pump (FP) and level sensor. Note! If carrying out work on fuel level sensor in a 5door 5 model, fold the rear seat forward, remove the front floor hatch screws (x 4) and pull hatch backward. Disconnecting hoses Separate connectors for fuel pump (FP) and level sensor Check color markings on hoses and pump. Note! The delivery pipe is marked with yellow tape. The pump has a corresponding color marking. Carefully disconnect quickrelease connectors on delivery and return hoses. Use tool Slide outer sleeve of connector upward. Avoid squeezing sleeve. Removal of rail under fuel lines, model year 1995 Pull down on the rail while simultaneously screwing out the plastic nut. Reinstall nut by pressing against the

2 "VCC EN " 2(6) neighbouring bolt and then tighten several turns. Removing fuel tank Remove: Circlip that tensions the rubber seal. Remove tank cover and rubber seal. Position mobile jack with fixture Use flat lifting table to avoid damage to internal tank components. Undo tank retaining straps and lower tank slightly. Removing hoses Disconnect EVAP system hose connector All hoses are secured in position by quickrelease clip on top of tank. Use screwdriver to undo top end of clip. Lower tank. Remove:

3 "VCC EN " 3(6) The two fuel tank hose connectors. The two screws on the flange retaining the fuel filler pipe. Pull out pipe with rubber seal and check valve. Removing fuel pump (FP) Remove nuts securing: Level sensor. Use wrench Use wrench Lift out: Fuel pump (FP) unit and level sensor. Caution! Lift unit straight up. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage. Remove seal. Installing fuel tank When installing a new fuel tank the following components must be replaced with new parts because the material swells. Failure to do so may result in fuel leakage.

4 "VCC EN " Level sensor nut (white) Level sensor nut seal Fuel pump (FP) nut (black) Fuel pump (FP) nut seal Fuel filler pipe seal. Transfer and install the two covers from the old fuel tank to then new one. Do not forget the selfadhesive tape on the left side of the rear plate. Installing fuel pump (FP) Install: Rubber seal on fuel pump (FP) unit and level sensor. Lubricate the inside and top of the seal with petroleum jelly. Install: Fuel pump (FP) unit Level sensor. Note! Check the seating of the fuel pump (FP) unit and level sensor using illustration. Install heater connector on the right and level sensor with cable on the left, see arrow. Note! Engine may stall if the fuel tank unit is installed incorrectly. Installing nuts Tighten large nut to 40 Nm. Tighten small nut to 30 Nm. Check level transmitter wiring as illustrated. Copyright 2004 Volvo Car Corporation. All rights reserved. 4(6)

5 "VCC EN " 5(6) Installing fuel filler pipe Install rubber seal, P/N on fuel tank collar. Lubricate inside of gasket and, if necessary, lower end of filler pipe. Check checkvalve is correctly positioned with its locking tab in position on pipe. Press pipe firmly into seal so that it slides into position. Install: filler pipe flange. screws. Tighten to 10 Nm. Installing hoses Reconnect hoses to fuel tank. See illustration for correct location. Tighten exhaust clamps to 3.5 Nm. Turn spring clamps so that they do not rub against the floor. Caution! Check nipple on top of tank. Installing fuel tank Rest tank and tank band on jack.

6 "VCC EN " 6(6) Use same fixture and lifting table as when removing tank. Raise tank and tighten tank band at rear. Push tank forward as far as possible. Center tank (see illustration) so that the level sensor nut (white) does not contact the edge of the opening. Tighten front tank band bolt. Press the clip with the fuel hoses into place on the tank band. Installing rubber seals Install filler housing around top of filler pipe. 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. Oil mating surface on the rubber cover (2). Install cover. Install the drain hose (3) last of all, otherwise water or fuel will enter the cargo compartment. Install the ring (4). Install panels and carpets.

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