P80 AWD fuel pipes for 99-00

[scot850]

I believe I am correct that all 99-00 cars will use these fuel pipes. The issue we have for these cars is many of the parts for the AWD rear end are steadily becoming obsolete.

Talking with abscate and his planned resurrection (for sainthood) of Ekaterina his AWD S70 he needed info on the fuel pipes so he could order materials as the fuel lines are I believe now NLA.

Fortunately I kept the old lines as templates when I did my renovations on my 2000 V70R AWD so I have added pictures below of the main pipes for references in case someone has to make up their own piping.

1) First up - Fuel line between left and right of saddle fuel tank

Left to right fuel pipe connector

This pipe connects the ejector on the front of the fuel tank on the LHS to the fuel pump assembly on the RHS front of the tank. This pipe and in particular the ends where it connects to the tank has bare metal pipes which are exposed and prone to rusting. The center section is coated with like a plasti-dip material which is about 1mm thick!

End of connector pipe

Other end of connector pipe

2) Main fuel pipe to the engine from fuel filter

This is the main pipe. This runs from just behind the RHS of the engine block with a fuel quick connect and runs back to the output of the fuel filter on the rear of the rear sub-frame. The pipe runs in a channel under the RHS of the car which is covered by a plastic cover.

Main fuel pipe

The long reinforced rubber hose that starts under the floor jack (approx. 6ft long) is the section from the hard-line up to the injectors at the rear of the engine and is covered in the channel under the floor to just forward of the fuel tank near the front of the RHS rear wheel

End of rubber hose for approx length

Rubber hose to LHS of the fuel filter

Metal section to fuel pressure regulator

Length of the rubber hose to fuel filter

Finally for this pipe there is the section of pipe that returns fuel to the fuel tank from excess to the engine. This and the fuel feed are controlled by the pressure regulator (the silver cylinder on the pipe). This is fitted on top of the tank forward of the rear axle on RHS. The fuel regulator has a plunger valve on the underside that pushes down through the plastic housing it sits on to control fuel pressure to engine. The 'free' end of the fuel regulator has a pipe that connects to it that runs back from the engine in the same channel as the fuel pipe to the engine in the channel under the floor.

The pipe from the fuel regulator then runs over the rear of the fuel tank and then around to the front and connects to the ejector unit on the LHS front of the tank. Note: For AWD P80's both the ejector and fuel pumps have level sensors that both need to work to give correct fuel tank levels as the average out both sides.

Fuel regulator to ejector pipe

The above picture is from a spare section of the pipe to make it easier to view.

Length of return pipe to ejector

Section of return pie on LHS of fuel tank top

Connection to ejector on LHS on tank front

I will add this section first so I don't loose all this and add more below

[abscate]

The Voluptuos Order Lady Victoria Oceania thank you for your Saintly work

[scot850]

Continuing on. Last major pipe is the pipe from the RHS front of the fuel tank from the fuel pump and runs backwards over the tank to the fuel filter on the rear of the rear sub-frame.

Fuel pump to fuel filter feed pipe

Note: There is a Schrader valve on the pipe just above the RHS of the rear axle and forward of the fuel filter which is just inside the RH rear wheel.

Overall pipe length

Pipe connection to the fuel filter

You can see the Schrader valve in the above picture.

Center section of pipe to fuel filter

This center section of the fuel pipe has a protective wrap over it.

Connection to fuel pipe

pipe connection to fuel tank

Emissions pipe on top of tank that is prone to failure:

There is a weird pipe on the top of the fuel tank to the rear that is I believe a overflow return. It has these weird cone shaped rubber bellow ends that tend to fail. Part is NLA. I have heard of people making thier own version using stepped diameters of pipes bonded together and clamped to the metal pipe

Breather - overflow pipe on top of tank

End of overflow pipe

If you look carefully you can see the middle of the bellows looking crusty. These have been in my garage for about 4 years.

Other end of the pipe

Vent pipe

If you see the smaller tank closer to the camera there is a rusty clamp on the lower LHS of it in the picture. This is one end of the vent pipe which then runs under a cover to the center of the fuel tank top.

Hopefully this will be of help to other and naturally if there are any questions or further detail required please let me know.



I've added a picture of the fuel tank viewed from the front of the car to help picture where the pipes go:

Fuel tank and pipes

More detail on fuel pipes

Neil.

[abscate]

Update on the cone shaped peice above, NLA part ???? ( they dont even give you the slightest glimmer of hope on Volvo parts web store)

It looks like the FWD car version of this piece, number 23 can be adapted.

[scot850]

Having corresponded with abscate I need to add some more detail on the fuel pipes.

The pipe below:

Fuel pipe from pump to fuel filter

The detail I missed with this is that it runs up the RHS of the carbon filter and connects to the RHS (when viewed from the rear of the car) of the fuel filter.

The other end (LHS) of filter is the feed line to the engine.

Main fuel line

If you look at the fuel filter connector on both pipes the connector can only fit one way to the filter.

Abscate was confused as it looks like (subject to his confirming possibly tomorrow) his fuel filter may have been fitted backwards with the flange pointing to the RHS not the LHS.

I am assuming that which was fitted to my 2000 R was connected the correct orientation with the flange to the LHS as seen here:

Fuel filter

Fuel filter (2)

These are the only pictures I can find showing the filter in place.

Hope this helps

Neil.

[abscate]

Yeah, mine is in backwards. I know these filters flow skinny -> fat end from opening them up, and my skinny end runs to front of car



On the fittings:


Maybe I will buy four lines from a junkyard to get the fuel pump fittings

2 on main fuel pump

2 on ejector pump.

[abscate]

This is an unverified post on how I believe fuel is routed on these AWD P80 cars

Fuel comes out of the RHS PUMP and goes to the rhs of the fuel filter. RED

Fuel from the LHs of the fuel filter comes down the pressure regulator YELLOW

The regulated pressure of 52 psi is sent forward TO THE ENGINE YELLOW

Excess is bled off to the LHS Venturi pump, and the LHs saddle tank is this pumped over to the right via the hard pipe connecting the LHs to the rhs

1A43E24D-9E93-4B4F-84EB-C6FAE0F37DF2.jpeg (1.62 MiB) Viewed 1837 times

[deano1]

Excellent work gentleman!
These pictures are worth a thousands of words now that everything is being obsoleted from Volvo.
When I had my 99 S70 awd apart a lot of the lines needed attention due to the amount of rust and new lines would need to be fabricated.
The nylon line that is grafted to metal lines lurks beneath the Multi layers of rubber Volvo protection can be a problem to work with so i tossed it in favour of easy to work with high pressure rubber fuel line.
I found 80's Ford nylon style connections are abundant and compatible and with Volvo only difference is you have a plastic "key" that slides into the connector and that secures it from sliding off.
That protective mesh wrap Volvo used must hold salt and moisture. That location of huge pipe corrosion/failure for me.
cheers Dean

[abscate]

I put as many hard line to rubber connections in accessible places as I could. Double oetiker clamps used throughout. I bridged the final feed hard line to to car fuel rail with hose and clamps. It lives up above the plastic cover but a fuel leak would quickly show by sight and smell.

Gates barricade fuel injection hose was used for all rubber hose. Good stuff , not cheap

Even more expensive when you use it cut as chafe protection.

[abscate]

One more view of the fuel delivery routing. The excess pressure from the fuel pressure regulator is used to push the fuel from the left hand saddle tank to the right, via the left hand fuel “ pump”