Fuel Tank: Service and Repair

Fuel tank, replacing

Special tools:
998 5972 JACK 998 5972 Jack
999 5972 FIXTURE 999 5972 Fixture
999 5720 Wrench 999 5720 Wrench
999 7017 Socket set rear axle 999 7017 Socket Set Rear Axle

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparation




Drain the fuel tank. See Fuel tank, draining Service and Repair.

Remove:
- the rubber seal around the fuel filler pipe
- the screw for the ground strip.




Applies to V70:
Lift up the right-hand seat cushion.
Remove the right side cushion. See Side cushion Side Cushion.
Applies to the S60:

Remove:
- the seat cushion. See Upholstery, seat cushion, replacing Upholstery, Seat Cushion, Replacing
- the right-hand side cushion. See Side cushion Side Cushion.
Applies to all models:
Disconnect the connector at the hinge.

Remove:
- the mounting screw for the hinge
- the screw for the hinge end mounting.
Release the strap/straps of the folding mechanism for the seat belt buckle. (Hooked into place on the lower edge of the backrest).
Lift out the backrest.

Removing the cover for the level sensor/fuel pump (FP)




Push the carpet to one side.

Remove:
- the insulation panel
- the cover (2).
Disconnect the connectors for the leak diagnostic pump and level sensor/fuel pump (FP).
Place the cable harnesses on the tank.

Removing the screws for the upper spring seat




Remove the cargo compartment carpet.
Disconnect and fold out the side panels in the cargo compartment.
Remove the seal above the shock absorber mounting on both sides.
Remove the two screws for the spring seat mounting on both sides.
Raise the car.

Note! Lift the sill edges so that the rear axle is free.

Removing the exhaust system

Remove:
- the exhaust system from the three-way catalytic converter (TWC) and backward.

Removing the heat deflector plate





Remove:
- the four plastic nuts
- the heat deflector plate.
Pull the handbrake cables from the clips on the tank.

Removing the brake calliper




Release the handbrake adjuster. See Handbrake, brake shoes, replacing Service and Repair.

Remove (on both sides):
- the wheel
- the ABS sensor and the ABS line from the bracket on the stub axle
- the brake calliper mounting screws.
Hang up the ABS line and the brake calliper. Use a piece of wire.

Removing the brake cable for the handbrake





Remove:
- the locating pin for the brake disc
- the brake disc
- the return spring at the expander
- the expander. Lift the brake shoe slightly. Grip the expander. Pull the expander outwards.
Unhook the expander from the metal bracket.





Remove (on both sides):
- the guide sleeve for the cable sleeve. Apply a screwdriver between the guide sleeve lug and wheel arch. Pry apart slightly to remove the sleeve.




Remove the handbrake cable from the track rod and the sub-frame on both sides.

Preparations for lowering the rear axle




Remove the evaporative emission system (EVAP) pipe from the clip between the tank and rear axle.




Remove the hose for the carbon filter from the tank.

Removing the rear axle




Remove the plastic nut for the wing liner. Bend the wing liner out of the way.
Drill out the heat deflector plate rivet on the sub-frame left rear bushing.




Remove the two screws for the spring seat mounting on both sides.




Position a lifting table under the rear suspension.

Warning! Always check that the car does not lift from the lifting arms of the car lift when working with the lifting table.

Remove:
- the four sub-frame mountings
- the sub-frame brackets screws
- the brake hose mounting stays from mountings on the brackets
- the brake pipes from the plastic clips.
Carefully lower the rear suspension approximately 50 mm.





Remove:
- the evaporative emission system (EVAP) hose (1)
- the leak diagnostic hose (2).
Pull the leak diagnostic pump (3) from the mounting.
Lower and remove the rear suspension.

Removing the tank




Position gearbox jack 998 5972 JACK 998 5972 Jack with plate 999 5972 FIXTURE 999 5972 Fixture under the tank.

Remove:
- the fuel line (1)
- the two screws for the front mounting (2) for the fuel tank.




Remove the evaporative emission system (EVAP) hose (1) from the clip mountings.
Remove the two screws (2) for the rear mounting for the fuel tank.
Lower and remove the fuel tank.

Tightening torque
For tightening torques, see Tightening torque Tightening Torque.

Transferring components




Transfer the venting pipe, leak diagnostic pump, pump control module and cable harnesses.

Transferring the fuel pump (FP)




Removal
Remove the cover.
Use special tool 999 5720 Wrench 999 5720 Wrench.




Remove the screw (1).




Carefully turn the pump to access the fuel hose (1).

Remove:
- the hose (1)
- the three connectors (2).
Carefully lift up the pump.

Note! Ensure that the level sensor arm is not obstructed. Do not bend the arm when removing the pump.

Installation
Lower the pump into the tank.

Install:
- the fuel hose
- the three connectors.
Turn the pump to the installation position. Install the mounting bracket and screw. (M6)
Install the cover.
Use special tool 999 5720 Wrench 999 5720 Wrench.
For tightening torques, see Tightening torque Tightening Torque.

Installing the tank
Use 998 5972 JACK 998 5972 Jack together with plate 999 5972 FIXTURE 999 5972 Fixture.
Carefully raise the tank.

Install:
- the two screws for the rear mounting for the fuel tank. (M8)
- the evaporative emission system (EVAP) hose in the mounting clips
- the two screws for the front mounting for the fuel tank. (M8)
- the fuel line.
Remove 998 5972 JACK 998 5972 Jack and 999 5972 FIXTURE 999 5972 Fixture.

Installing the rear suspension
Raise the rear suspension until the spring seats enter the holes in the chassis.

Note! Do not trap the hoses, lines or brake components when raising the rear suspension.

Install:
- the leak diagnostic pump in its mounting
- the leak diagnostic hose
- the evaporative emission system (EVAP) hose.
Raise the rear suspension further so that there is a 20mm gap between the chassis and the sub frame bushing.

Warning! Always check that the car does not lift from the lifting arms of the car lift when working with the lifting table.

Install the screws for the upper spring seat. (M10)
Slide up the centring sleeves 999 7017 Socket set rear axle 999 7017 Socket Set Rear Axle in the two rear mountings on the sub-frame.

Install:
- the screws. Tighten lightly
- the screws for the front mountings on the sub-frame (install the screws through the brackets).
Tighten all front mountings. (M12)
Remove the screws for the rear mountings on the sub-frame. Remove the centering sleeves.
Install the screws for the rear mountings on the sub-frame again. Tighten. (M12)
Remove the lifting table.

Install:
- the brake pipes in the plastic clips on the brackets
- the screw for the brake line mounting stay. (M8)
- rivets to the heat shield on the sub-frame left rear bushing
- the plastic nut for the wing liner
- the hose for the carbon filter on the tank
- the evaporative emission system (EVAP) pipe between the tank and rear suspension.

Installing the brake cable for the handbrake
Applies to both sides:
Install the mounting for the cables on the sub-frame and the clips on the tie rods.
Thread the mechanical cables into the brake covers.

Hint: Lubricate the O-rings on the guide sleeves of the mechanical cables. Use silicone grease.

Note! Ensure that the guide sleeve lug is correctly positioned in the cover.

Hook the expander in the plate bracket.

Install:
- the expander
- the return spring
- the brake disc
- the locating pin for the brake disc. (M6).

Installing the brake calliper
Applies to both sides:

Install:
- the brake calliper
- the brake calliper mounting screw. Use new screws.
For tightening torques, see Tightening torque Tightening Torque.

Install:
- the ABS sensor
- the screw. (M6)
- the ABS sensor cable in the bracket
- the wheels. See Installing wheels Service and Repair.

Installing the heat deflector plate

Install:
- the heat deflector plate.
- the four plastic nuts
- the handbrake cables from the clips on the tank.

Installing the exhaust system
Install the exhaust system starting from the three-way catalytic converter (TWC) and working backward.

Installing the screws for the upper spring seat

Install on both sides:
- the two screws for the spring seat mounting
- the seal above the shock absorber mounting
- the side panels in the cargo compartment.
Install the cargo compartment carpet.

Installing the cover for the level sensor/fuel pump (FP)
Connect the connectors for the leak diagnostic pump and level sensor/fuel pump (FP).

Install:
- the cover
- the insulation panel.
Reinstall the carpet.

Finishing

Install:
- the backrest
- the screw for the hinge mounting (M10)
- the connector for the hinge
- the end mounting for the seat belt.
For tightening torques, see the relevant specifications.
Install the side cushion.
(V70) Fold the seat cushion forward.
(S80, S60) Install the seat cushion.

Install:
- the screw for the ground strip.
- the rubber seal around the fuel filler pipe
Top up the fuel.