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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
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rugbygrrl_15
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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 viewtopic.php?t=60291#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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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

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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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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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abscate

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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Part Duex! 98 S70-Advice for Gasket & Filler Pipe replacement

Post by rugbygrrl_15 » Fri Aug 02, 2019 8:34 am

Erik or any of you terrific folks,

Yesterday I was more than an hour into jacking the car up, labeling wires and hoses, and encountered a problem.

I started to lower the gas tank but the front portion wouldn’t drop with the rear. In “how to” guide a 10mm clamp is mentioned in the section describing disconnecting the fuel pump wires. I couldn’t find the mentioned 10mm clamp on my 98’ S70 base. I am looking inside my trunk near the fuel pumps, but I think I’m look in the wrong spot.

Anyone know of the 10mm clamp of which I speak? *doth thou?* Or why the front of my gas tank isn’t dropping with the rear section after unbolting the gas tank straps?

I really don’t want to yank anything down because I cannot have a fuel spill (I’m sure I will get evicted), but I also don’t want the shame from needing to tow car to the mechanic (again) cause I broke something.

Lifeline please!
Senny



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

Post by erikv11 » Fri Aug 02, 2019 9:54 am

Did you remove the two torx screws holding the filler neck in place? You access those under the fuel door, from the outside of the car. And the wires are all unhooked from the pump?

Oh OK I think I see, I looked at the cn90 write-up - For the 10mm clamp bolts, the write-up is cryptic but that probably refers to the clamp that secures the neck to the tank. It's position is circled in the NEXT photo, after the clamp is mentioned in the write-up. The clamp has nothing to do with the wiring and is only accessible from under the car, not from the top like the wires.

That clamp tends to be rusty and corroded, be sure to use penetrating oil if you undo it. However it is also not completely necessary to remove, this just makes it easier to separate the tank from neck after you drop it.

I wonder if the metal straps are just sort of stuck to the tank?
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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

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

Post by erikv11 » Fri Aug 02, 2019 10:07 am

And I hope it is not too woefully late to bring this up but, a very common source of leaks at the fuel pump is an aging fuel pump gasket. Are you going to check/replace hoses on top of the tank, is that your thinking here? Should have asked this earlier, oops!


'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

rugbygrrl_15
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rugbygrrl_15

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

Post by rugbygrrl_15 » Fri Aug 02, 2019 1:18 pm

erikv11 wrote:
Fri Aug 02, 2019 9:54 am
Did you remove the two torx screws holding the filler neck in place? You access those under the fuel door, from the outside of the car. And the wires are all unhooked from the pump? Yup, Torx off, Wires, disconnected, wire circlip that holds rubber cover on filler neck, removed

Oh OK I think I see, I looked at the cn90 write-up - For the 10mm clamp bolts, the write-up is cryptic but that probably refers to the clamp that secures the neck to the tank. It's position is circled in the NEXT photo, after the clamp is mentioned in the write-up. The clamp has nothing to do with the wiring and is only accessible from under the car, not from the top like the wires. Ok, thanks for helping me with this part. I’m also wondering if it could be an Evap system hose connector that’s still connected. My S70 sometimes thinks it’s an 850, like how the Evap canister is at the front of the car, instead of at the rear like MOST S70s.Thanks for not recommending yanking it down! :D I’ll keep you updated.



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

Post by rugbygrrl_15 » Fri Aug 02, 2019 5:35 pm

erikv11 wrote:
Fri Aug 02, 2019 10:07 am
And I hope it is not too woefully late to bring this up but, a very common source of leaks at the fuel pump is an aging fuel pump gasket. Are you going to check/replace hoses on top of the tank, is that your thinking here? Should have asked this earlier, oops!
I'll keep the gasket in mind. When I initially had a look in the area around the fuel pump there didn't seem to be any leaks or staining of the plastic. Then I had a gander at the gas tank underneath my car facing the trunk and I noticed some discoloration at the clamp where the filler hose goes into the tank. Very similar to the picture in the guide. I'm thinking this maybe the source of my P0442 code. God I really loathe Evap and Vac leaks, its like finding hen's teeth.
Thanks very much for the help! :)



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