Removal (C/S/V70, FWD)

Use draining unit (981 2270, 2273 and 2282), to drain fuel from tank. Cut end of hose at an angle to get past all sharp edges. Insert hose at least 3.2' to reach fuel in tank.
On wagon models, fold up front floor hatch, and fold back carpet. Remove cover over fuel pump unit. On sedan models, fold forward right rear seat. Remove cargo compartment carpet and right wheel arch panel. See Fig 1. Fold back corner of wheel housing panel at shock absorber mounting. Remove cover over fuel pump and level sensor.
On all models, disconnect all connectors on bracket. See Fig 2. Remove rubber bracket around wiring. Remove fuel filler pipe ground lead from nut on fuel tank level sensor cover. Ensure all cables routed through fuel pump unit holes are free to follow fuel tank when lowered.

NOTE: Delivery hose is marked with yellow tape, Pump has a corresponding color marking.

Check color marking on hoses and pump. Separate connectors for fuel pump and level sensor. Carefully disconnect quick-relaease connectors on delivery and return hoses. Using Volvo holder (999 5533), taking care not to squeeze sleeve, slide outer sleeve of connector upward. See Fig 3.
Remove fuel tank filler cap. Remove circlip securing rubber seal. See Fig 4. Release rubber seal from bodywork. Disconnect terminal/inlet hose. See Fig 5.

CAUTION: Use flat lifting table to avoid damage to internal tank components when lowering fuel tank.

Position mobile jack with fixture (999 5972) under fuel tank. See Fig 6. Ensure lifting platform is flat. Undo tank retaining straps, and slightly lower tank.

NOTE: Note hose position in clamp. Hoses must be reinstalled in original positions.

Disconnect hose between EVAP canister shut-off valve and air cleaner from fuel tank clamp. Cut off fuel filler pipe tie straps. Disconnect hose, air cleaner and protection from fuel filler pipe and place aside. Pull entire mounting from bracket towards right of vehicle, and remove.
Slightly lower fuel tank again. All hoses are secured in position by quick release clip on top of tank. See Fig 7. Use screwdriver to undo top end of clip. Lower tank.
Disconnect hose connectors to fuel filler pipe. Remove two screws on flange retaining fuel filler pipe. See Fig 8. Pull out pipe with rubber seal and check valve. Remove fuel tank pressure sensor screw. See Fig 9. Remove clamp.
Using wrench (999 5486), remove level sensor nuts. See Fig 10. Using wrench (999 5485), remove fuel pump. Lift fuel pump and level sensor our and remove seals. See Fig 11.