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98 S70-Advice for Gasket & Filler Pipe replacement

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
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

rugbygrrl_15
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rugbygrrl_15

98 S70-Advice for Gasket & Filler Pipe replacement

Post by rugbygrrl_15 » Fri Jul 12, 2019 12:35 pm

I have the dreaded P0442 and tried all the easy fixes but alas I believe my car is throwing this code because of a small leak at the gas tank/filler pipe. I am thinking of attempting the DIY fix posted https://www.matthewsvolvosite.com/forum ... 91#p307503but I have a few questions to ask of my peers that have done this fix.
  • I'm a chick=weaker than most guys. I have 1 floor jack, 2 bottle jacks, 2 jack stands, and access to lumber.
    If I run my car as close to dry as possible, "Do you think I have enough gear to drop my empty gas tank, preform the repair, and lift the tank back into place?"
    Is there anything else you suggest I have/get to make this repair and stay safe while making this repair?
    Should I suck it up and have my mechanic do this fix because the hazards out weigh the $ savings?
Thanks everyone! :D
S



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erikv11
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erikv11

Re: 98 S70-Advice for Gasket & Filler Pipe replacement

Post by erikv11 » Fri Jul 12, 2019 1:03 pm

rugbygrrl_15 wrote:
Fri Jul 12, 2019 12:35 pm
...
  • I'm a chick=weaker than most guys. I have 1 floor jack, 2 bottle jacks, 2 jack stands, and access to lumber.
    If I run my car as close to dry as possible, "Do you think I have enough gear to drop my empty gas tank, preform the repair, and lift the tank back into place?"
    Is there anything else you suggest I have/get to make this repair and stay safe while making this repair?
    Should I suck it up and have my mechanic do this fix because the hazards out weigh the $ savings?[/list
    ...
I speculate you can handle lowering and raising the tank, anyway I always leave that part mostly to my floor jack (and a square board e.g. plywood piece - don't make the foolish and avoidable mistake of just using one 2 x 4!). The tank is surprisingly light when close to empty. Run it down to a couple gallons (6 pounds per gallon of gas) and the whole thing is then maybe 20 pounds. You can even siphon out more fuel by pulling the fuel filter, but use a hand siphon don't mouth siphon it.

The trickier part of gas tank-related repairs is if you have to thread hoses/wires back up over the tank, this mostly requires patience. And repositioning the metal retaining straps can be a hassle but if the tank is light you will get them back in place. Get the back of the car up in the air (safely) so you can move around under there.
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rugbygrrl_15


'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 140k
'98 S70 NA, 210k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 280k
'06 S60 R, 160k
gone: '96 NA 850 210k, '98 NA V70 182k

cn90
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Re: 98 S70-Advice for Gasket & Filler Pipe replacement

Post by cn90 » Fri Jul 12, 2019 6:51 pm

I am the person that posted that DIY in 2013. Time flies.

I admire the fact that you want to tackle this job.
It is not difficult, being slow and methodical is the key.

As erik said above, do NOT use only a 2x4, which was exactly what I did in that photo (in the link you posted).
Use a piece of plywood.
You already have all the tools mentioned.

Get 2 second person to help...

PS: a secret trick: whenever disconnecting any hose, use masking tape and label #1 (or #2 etc.) on both sides: the metal pipe and the hose side. This way it will be a breeze when you re-install things.
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rugbygrrl_15


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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wizechatmgr
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wizechatmgr

Re: 98 S70-Advice for Gasket & Filler Pipe replacement

Post by wizechatmgr » Fri Jul 12, 2019 7:13 pm

cn90 wrote:
Fri Jul 12, 2019 6:51 pm
I am the person that posted that DIY in 2013. Time flies.

I admire the fact that you want to tackle this job.
It is not difficult, being slow and methodical is the key.

As erik said above, do NOT use only a 2x4, which was exactly what I did in that photo (in the link you posted).
Use a piece of plywood.
You already have all the tools mentioned.

Get 2 second person to help...

PS: a secret trick: whenever disconnecting any hose, use masking tape and label #1 (or #2 etc.) on both sides: the metal pipe and the hose side. This way it will be a breeze when you re-install things.
^^^This... I once rebuilt a subaru engine and misattached the fuel supply and return. Took me a bit of time to figure out but the anguish has lingered. Also take pictures as you're disassembling, it will help you in a positioning jam during reassembly.
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In order to learn how to fix something, you must first learn how to break it.
1999 V70 XC AWD - ~177k miles

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abscate
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Re: 98 S70-Advice for Gasket & Filler Pipe replacement

Post by abscate » Fri Jul 12, 2019 7:29 pm

I'm a chick=weaker smarter than most guys.
Should I suck it up and have my mechanic do this fix because the hazards out weigh the $ savings?

>> See above!

A helper is useful but the tank itself isn't that heavy. You can get the tank down to when the low fuel light comes on (you didn't know it had that did you....see above, again) and you are down to about 2-3 gallons.

You can jump the fuel pump relay and pump the tank to almost empty into a red gas can you can borrow. We can point you to directions on how to do that.
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