Replacing Fuel Tank Components

If replacing fuel tank components, remove fuel tank pressure valve. Remove splash guard pipe and pull straight out. Remove level sensor. Disconnect electrical connector and ejector. Grip right-side level sensor and hold float arm in lowest position. Carefully work holder up out of tank. Pull hoses and wiring out of tank. See Fig 1.

Fig 1: Disconnecting Lines & Sensors From Fuel Tank (S80)
Courtesy of VOLVO CARS OF NORTH AMERICA.
If necessary, remove tank retaining straps and heat deflector. See Fig 2. Fit retaining straps and deflector to new tank. Tighten heat deflector bolts to specification. See TORQUE SPECIFICATIONS . Tighten retaining strap bolts to specification.

Fig 2: Fitting Straps & Heat Shield To New Fuel Tank (S80)
Courtesy of VOLVO CARS OF NORTH AMERICA.
Fit sealing ring and route cable harness and hoses from right level sensor to left side of tank. Use a curved rod with a hook at one end to pull harness and hoses to correct position. Install left-side sealing cover and ejector. Connect electrical connectors and level sensor. Tighten sensor to specification. See TORQUE SPECIFICATIONS . Use Level Sensor Wrench (999 5720) or equivalent. Ensure mark on sensor lines up with marks on tank. Install right-side level sensor using same procedure. See Figure.
Install splash guard pipe. Ensure locating pin is correctly positioned. Install fuel tank pressure sensor. Fit holding screw and hose clamp. See Fig 3.

Fig 3: Fitting Splash Guard Pipe & Pressure Sensor (S80)
Courtesy of VOLVO CARS OF NORTH AMERICA.