Gas Tank Removal Question + Leak photo

Post by **outdoor7or24** » 20 Oct 2009, 16:12

1995 855t with a leaking hose on top of the gas tank. The yellow X is where the gas spews out when filling it up.

My question is on how to drop the gas tank. Anything special?
Any idea on the steps?

Anything else I need to replace while the tank is dropped?

Thx.

volvomileage · Post by **volvomileage** » 21 Oct 2009, 18:32

hello

although i have never removed the tank i joined a pdf, hope it can help you out

cheers !

Post by **outdoor7or24** » 21 Oct 2009, 20:01

volvomileage wrote:hello

although i have never removed the tank i joined a pdf, hope it can help you out

cheers !

Thanks for the pdf. However, I didn't see much in it for removal of the gas tank.
This did make me remember about the manual for download on this site though...

voodoorobaz · Post by **voodoorobaz** » 21 Oct 2009, 20:22

Just don't fill it all the way up...Just kidding. is it possible to lower it just enough to get to it? enough hose left to cut off bad part or you wanna replace entire hose? Had a leak like that myself on a diff car and that's what I did. Not sure on this particular car...

Post by **outdoor7or24** » 24 Oct 2009, 06:44

Anyone here dropped the fuel tank? Just wondering if there are any surprises....

Post by **renns** » 28 Oct 2009, 18:29

My 850 leaks if filled to the max as well. I'll watch this thread to see what I'm up against. So far I'm stopping the fueling as soon as the filler valve kicks off the first time. If I don't, that last litre or so that I add will end up on my garage floor by morning.

Post by **outdoor7or24** » 02 Nov 2009, 19:29

Done.

I took some photos along the way and will post a 'how to' this week with those photos.
It was easy to remove, but a little harder to put back in place.

Post by **outdoor7or24** » 11 Nov 2009, 07:54

Folks sorry for the delay... House renovation and traveling.
Here is the write-up.
I followed a link on volvospeed.com - - as a reference. Mine was a little different.

1. Disconnect the negative battery cable for safety.
2. Block the front wheels, jack up the rear, use some jack stands to hold up the rear.
3. Remove the floor board to open up the area to access the top of the fuel pump and sender.

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4. Unbolt the cover over the fuel pump and sender. Unhook the electrical connectors so they can go through the hole when dropping the tank.

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5. There is a circlip that holds the fuel filler in the door. Pop this out so you can lower the tank with the fuel filler. Just push out the rubber seal so it comes out of the fuel door hole.

6. Line up a floor jack to support the gas tank when you unbolt the supports. There are 3 bolts that hold up the metal band supports. Unbolt them and use your floor jack to slowly lower the tank while guiding the fuel filler tube as you slowly lower the tank. Move the metal bands out of the way and lower the tank. Make sure your electrical connectors come through the holes without getting hung up.

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7. With tank down, you should be able to slide the jack out and and replace the cracked hose under the car.

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8. The Cracked hose. It just poured fuel out when the tank got full.

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9. This is where I noticed my hose was different than the volvospeed.com post. I had a molded rubber hose that had ends with different sizes. I got some 3/4 inch fuel hose that would fit on the tank vent hole end. I cut out a good section of the original hose and slid the 3/4 hose over this, used a little JB Weld to seal the end, added a hose clamp and put 'er back in place. So far this has worked. However I noticed I cannot use the fuel pump at full speed due to fuel backing up.

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10. After hooking up the hoses, get your tank back on the floor jack and begin the process of raising the tank. Make sure your jack is not in the way of the metal supports. Guide the filer hose back up to the filler door as you jack up the tank. As the tank gets higher, work the electrical connectors back through the hole.
I started the front bolt first and found that to be the best. Just get a few threads started on the front bolt and then work on getting the rear bolts. I found the passenger rear bolt the hardest FYI.

I may come back and add a few things....

Post by **matthew1** » 11 Nov 2009, 09:38

Very good writeup, thanks outdoor. Your rank = "MVS Contributor" and this is now pinned this in the Volvo Repair Database.

Post by **outdoor7or24** » 11 Nov 2009, 18:55

matthew1 wrote:Very good writeup, thanks outdoor. Your rank = "MVS Contributor" and this is now pinned this in the Volvo Repair Database.

Sweet! Thx.
I hope this helps out folks and glad I could give back some knowledge on the forum. MVS has helped me!