Fuel Tank: Removal

Drain fuel tank using draining unit (981 2270, 2273 and 2282). See Fig 1.

Fig 1: Draining Fuel Tank
Courtesy of VOLVO CARS OF NORTH AMERICA.
Insert hose filler pipe at least one meter in order to reach the fuel.
Cut the end of hose at an angle to get past all sharp edges.
Remove panels on 5-door cars, fold up the front floor hatch and fold back carpets. See Fig 2
For 4-door cars, remove the following:
- Cargo compartment carpet. See Fig 2.
- Right wheel arch panel. Fold back the corner of panel on variants with soft panels.
- Covers over nuts to fuel pump and level sensor.
  
  Fig 2: Removing Access Panels
  Courtesy of VOLVO CARS OF NORTH AMERICA.
NOTE: The delivery pipe is marked with yellow tape and the pump has a corresponding color marking.
Disconnect hoses by separating connectors for fuel pump and level sensor. See Fig 3. Check color markings on hoses and pump.

Fig 3: Identifying Fuel Pump Connectors
Courtesy of VOLVO CARS OF NORTH AMERICA.
Disconnect quick-release connectors on delivery and return hoses using Injector Valve Clamp (999 5533).
Slide outer sleeve of connector upward avoiding squeezing sleeve.
Remove rail under fuel lines. Pull down on rail while simultaneously screwing out plastic nut. See Fig 4. Reinstall nut by pressing against the neighbouring bolt and then tighten several times.

Fig 4: Removing Rail Under Fuel Lines
Courtesy of VOLVO CARS OF NORTH AMERICA.

NOTE: Use flat lifting table to avoid damage to internal tank components.
Remove fuel tank. Remove circlip that tensions the rubber seal. See Fig 5.

Fig 5: Removing Seal Circlip
Courtesy of VOLVO CARS OF NORTH AMERICA.
Remove tank cover and rubber seal. See Fig 6. Position mobile jack with fixture using Fixture tool 999 5972. Undo tank retaining straps and lower tank slightly.

Fig 6: Removing Fuel Tank
Courtesy of VOLVO CARS OF NORTH AMERICA.
Remove hoses. Disconnect EVAP system. See Fig 7. All hoses are secured in position by quick-release clip on top of tank. Use screwdriver to undo top end of clip. Lower tank.

Fig 7: Disconnecting EVAP System Hose
Courtesy of VOLVO CARS OF NORTH AMERICA.
Remove the following:
- Two fuel tank hose connectors. See Fig 8.
- Two screws on the flange retaining the fuel filler pipe.
- Pull out pipe with rubber seal and check valve.
  
  Fig 8: Removing Fuel Tank Filler & Pipe
  Courtesy of VOLVO CARS OF NORTH AMERICA.
Remove nuts securing level sensor and fuel pump using Level-Sensor Nut Wrench (999 5485) and Fuel-Pump Nut Wrench (999 5486). See Fig 9.

Fig 9: Removing Fuel Pump
Courtesy of VOLVO CARS OF NORTH AMERICA.

CAUTION: Lift unit straight up. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in leakage.
Remove fuel pump unit and level sensor from tank. Remove seal. See Fig 10.

Fig 10: Lifting Fuel Pump Out
Courtesy of VOLVO CARS OF NORTH AMERICA.