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DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank! Topic is solved

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
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cn90
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Volvo Repair Database DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!  Topic is solved

Post by cn90 » Fri Nov 22, 2013 8:27 pm

I have a Fuel Leak, which leaks from the top of the gas tank. I think it is from the Vent Hose.

I benefited from this DIY (Laparoscopic Fuel Hose DIY):
http://www.matthewsvolvosite.com/forums ... =1&t=54739

If you want to drop the gas tank, here it is:
http://volvo850wagon.wordpress.com/tag/hose-2/

So, here is my version. If you do it this way (drilling a small 3/8-inch hole), there is no need to drop the gas tank!

PN 9463088 (#23 in the photo): Hose on top of gas tank ~ $19.

1. See the Fuel Leak.

Image


2. Parts Diagram.

Image


3. Remove all the junks from your trunk. Pry the plastic clips, lift up the carpet, remove the 10-mm nuts. BTW, get a box to store all the odds and ends, as they can fall down the spare-wheel well!
* You can see the area of fuel leak. Note that the hose has 2 different I.D.s (3/8-inch and 5/8-inch).
VolvoFuelTank02.JPG
VolvoFuelTank03.JPG

4. Overlay the new hose, so you have an idea where to drill the 3/8-inch hole.
VolvoFuelTank04.JPG

If you drop the gas tank, this is what it looks like (I borrow this photo from the web):
VolvoFuelTank05.JPG

5. Use small drill bits and work your way up to 3/8-inch bit (wear goggles!). Once the hole is drilled, insert a small screwdriver to undo the clamp.
VolvoFuelTank06.JPG

6. Next don’t yank the hose as you may damage the Plastic Blue Connector. Instead, use Vise-grip to twist (rotate) the hose to undo the “bonding”. Now, remove the hose:
VolvoFuelTank07.JPG

7. New hose is a bit tight, given the tight space you have to work with, so 2 tricks will help with the installation:
a. Enlarge the end with a socket, let it sit for a few minutes so the hose gets used to the enlargement.
b. Once done, add 2-3 drops of fresh oil to ease insertion. Don’t forget the clamps!
VolvoFuelTank08.JPG

8. Note the clamp as viewed through the hole.
VolvoFuelTank09.JPG

9. On the outside, somehow a small vent hose became disconnected (it was a loose fit). I re-inserted it and add 2 zip ties to prevent it from coming loose again:
VolvoFuelTank10.JPG

10. For the final touch, I used some black paint and paint the hole to prevent rust. Let the paint dry, then use a Honda body clip (3/8-inch type, same size as the drill bit) that I had laying around to close the hole:
VolvoFuelTank11.JPG

All in all, it is a 1h job, not to bad as you don’t have to deal with dropping the gas tank, not mention that you have to deal with rusty nuts/bolts holding the straps for the gas tank!

Remember to leave the 2 metal covers (that cover the sending unit and fuel pump) off for now while you fill the gas tank to full to check for leak.

That is it boys and girls!
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misha
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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by misha » Fri Nov 22, 2013 8:50 pm

Interesting write-up. :wink:


'97 850 2.5 20v /fully equipped/ Motronic 4.4 / polar white wagon
'91 Citroen XM 2.0 SI /fully equipped/mandarine red metallic
History of Volvos in the family:
'71 144 S
'73 144 De Luxe
'78 244 DL
'78 244 DL
'79 244 GLE
'85 340 GLS

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rspi
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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by rspi » Sat Nov 23, 2013 2:31 am

So the sending unit and pump have different access ports?


'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
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Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by beigg » Sat Nov 23, 2013 6:36 am

Yes, different locations that use different ports.


ugh smh 850 Turbo fridge

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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by Goldponcho » Sat Nov 23, 2013 11:55 am

Great write-up! This is an issue on my '95, and with the cold weather it'll be nice to tackle this in the garage without dropping the tank. Now to order that hose......



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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by ashlee2319 » Sat Nov 23, 2013 8:28 pm

Sorry to jump in, but question. In the picture on "#4", what is inside the top circular smaller panel? Above the fuel pump. I opened mine up the other day and was just curious to what it was.



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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by ashlee2319 » Sat Nov 23, 2013 8:31 pm

Oh wait sorry, i see... The top of the fuel tank, duh.
Is that cover supposed to come off? I was able to wiggle mine around a little..



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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by rspi » Sun Nov 24, 2013 11:47 am

Very nice cn90, keep up the good work.


'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by matthew1 » Sun Nov 24, 2013 1:05 pm

Wow, amazing skill/imagination on this, CN. Scheduled for inclusion in the VRD.


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cn90
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Re: DIY: 1998 S70 GLT Fuel Vent Hose w/o Dropping Gas Tank!

Post by cn90 » Wed Nov 27, 2013 10:59 pm

I want to consolidate all gas tank leak issues into one place to make it easier for future readers, so there are basically 4 potential places for fuel leak at the gas tank area:

1. EVAP Hose Leak is this very same thread.


2. Gasket at Gas Tank & Filler Pipe:
http://www.matthewsvolvosite.com/forums ... hp?t=60291


3. Fuel Pump Rubber Seal:
http://www.matthewsvolvosite.com/forums ... hp?t=60329


4. Fuel Pump Wiring area:
Hint: if you see fuel in the wiring area (especially after a fill-up), chances are it leaks through the areas where the 2 wires enter the fuel tank via the top plastic cover.
This leak can be so bad (dripping on the ground after a fill-up) that it can fool you into thinking that the cause is any of the 3 items above!
http://www.matthewsvolvosite.com/forums ... hp?t=24518

By far, #4 is the easiest and simplest fix: simply use a small screwdriver to remove old "wax", then apply "Butyl Rope" and press it down to seal. This is what I just did and it is bone-dry now.
So start with the simple thing first!


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2005 XC90 2.5T 110K+

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