Service Manuals & Fuel Capacity

oldacura · Post by **oldacura** » 01 Oct 2008, 16:03

I recently bought a 2001 V40. I've been looking for a service manual. Is there a "best" manual (Haynes or HP Books)?

Also, I have filled the tank twice. The owner's manual shows the tank should hold 16 gallons. The second time I filled it after the low fuel light came on (about 300 miles). I was able to get just over 11 gallons in. This figures to be about 27 mpg but it seems like the tank is only about 12 gallons. Is there something wrong with my tank?

Thanks!

Post by **billofdurham** » 04 Oct 2008, 12:30

Welcome to Matthew's Volvo Site.

I don't know HP books but Haynes manuals are usually good enough for DIY tasks.

The fuel tanks on this model have caused much scratching of heads and dark mutterings from other owners.

Reports such as yours are commonplace on most Volvo forums and, as far as I know, no-one has come up with an answer.

The only thing that comes to mind is that once the level in the tank passes a certain point when you are re-fuelling the pump cut-off is activated by air going into the nozzle. I have had this happen on some Vauxhalls in the past and I found that easing the nozzle a little way out of the filler would start the flow again.

Bill.

oldacura · Post by **oldacura** » 06 Oct 2008, 08:12

Thanks for the response. I spoke with 2 people here at work with 2001 Volvos - a V40 & an S40. They both said the most gas they had ever put into their tanks was about 12 gallons. The last time I filled, I took care to really top it off. Once the nozzle shut off, I rocked the car and withdrew the nozzle and ran some in slowly. Still - only 11.4 gallons.

My guess is that the owner's manual saying the tank is 16 gallons is a misprint.

Thanks again for your reply. So far it seems like very few people respond on the Volvo forums.

Erics40 · Post by **Erics40** » 08 Oct 2008, 07:49

I too have discovered the short tank. I am now running the tank dry to see how far I can go. I will post results when I have info.

Post by **billofdurham** » 08 Oct 2008, 11:51

Erics40, welcome to Matthew's Volvo Site.

I hope you are carrying a can of fuel for when you do run dry.

It will be interesting to see how much you do need to fill the tank. I have tried calculating in US gallons, Imperial gallons and litres and can't see how Volvo can claim a 60 litre tank only holds about 45.

The later models have been reduced to a 55 litre tank but it would appear that you can't even get that amount in.

Bill.

Erics40 · Post by **Erics40** » 09 Oct 2008, 07:29

Hi all,

Well, the great gas tank experiment is over. I ran the car to empty and got 474 miles, validating the owners maunal. I have been getting about 30 mpg so this mileage proves the 16 gallons in the tank and a smidge under 30 mpg. Yes I did have a 1 gallon can in the trunk.

So now the head scratcher. The float must bottom out in mid-tank with 6 gallons left. My next foray will be to autopsy the sender/float to see if it can be extended or fooled. If not, it's back to to old days of mototcycle or guageless VW: calculate the tank using the odometer and ignore the guage. For the moment I'm going to use 425 miles as the fillup time.

Hah, I am smarter than a fuel guage!

Best regards, Eric.

Post by **billofdurham** » 09 Oct 2008, 12:52

Eric, thank you for the update.

I am not sure how you can alter the fuel sender. Bend the arm to make it go lower in the tank but then it will probably never read 'full'.

As I said earlier, this is a question asked on many Volvo forums and I have never seen an answer to the problem.

I now wonder if any of the dealers who have been approached by owners have queried this with Volvo Cars. I suspect not. It may pay to try contact with Volvo direct.

Bill.

oldacura · Post by **oldacura** » 10 Oct 2008, 12:17

I filled mine yesterday. It was down near "E" with 312 miles on the tank. Took about 10.9 gallons to fill. Once the pump shut off, I shook the car and ran a bit more in slowly. It only took a fraction of a gallon more.

When I drive the car, the needle falls off the FULL mark after only about 20 miles. I'm not sure that I'm getting the tank really full. On the other hand, maybe the gauge is mis-calibrated and I could really drive another 170 or so miles. I doubt that I will ever try this. Probably just be careful and fill when it gets to "E".

Erics40 · Post by **Erics40** » 12 Oct 2008, 19:59

Hi Bill,

Thanks for the continuity. More on the sender and fuel level issue-

The pictures of the sender show a float and a wire that may be able to be bent to accommodate the sender electronics. It seems the float is actually two thirds of the travel, so I may pull it to see if it will go that far. It needs space in the tank and possibly a longer arm.

"Do not try this at home" sure applies here: I may have to weld a longer wire for the float. I haven't decided if it's worthwhile yet because the wife will seldom drive it and we both can use the odometer for range.

Does anybody know how to move the steering wheel back a bit? I'm a tall guy and can barely reach it without slouching.

Eric.

Post by **billofdurham** » 13 Oct 2008, 12:48

The only adjustment I can find for the steering wheel is vertical.

If you can get an arm extension to get into the fuel tank buy two.

Bill.