Gas Tank Removal Question + Leak photo

jpeisker · Post by **jpeisker** » 22 Nov 2009, 20:31

Regarding the two different sizes of hose ends (item 9 in the replacement procedure):
The large end tube measures 18.5mm (0.73") OD and the new hose ID is 16mm (0.63") or so. The smaller end tube measures 12mm (0.47") OD and the new hose is 10.5mm (0.41") ID.
So I would bet that if you could find any fuel hose with a 5/8" (exact) or 3/4" (loose, but may work when clamped tight) opening on one end and 3/8" (close but tight) or 1/2" (loose) at the other it would work.
The factory hose has a couple of gentle bends but straight hose should work fine if you can find something like fuel-rated 5/8" to 3/8" at an auto parts store.

Post by **outdoor7or24** » 23 Nov 2009, 05:05

jpeisker wrote:Regarding the two different sizes of hose ends (item 9 in the replacement procedure):
The large end tube measures 18.5mm (0.73") OD and the new hose ID is 16mm (0.63") or so. The smaller end tube measures 12mm (0.47") OD and the new hose is 10.5mm (0.41") ID.
So I would bet that if you could find any fuel hose with a 5/8" (exact) or 3/4" (loose, but may work when clamped tight) opening on one end and 3/8" (close but tight) or 1/2" (loose) at the other it would work.
The factory hose has a couple of gentle bends but straight hose should work fine if you can find something like fuel-rated 5/8" to 3/8" at an auto parts store.

I tried 5/8" and it would not work on the larger end... Just so you know.
Only 3/4" would slide on the larger end (then fuel tank side).

Post by **pkc303** » 17 May 2010, 21:50

Well, we dropped our tank, and changed the fuel hose going to the fuel filter. The elbow broke, and the dealer wanted a lot of money for another hose. The quick connect is attached to the hose, and there really is no way to replace just quick connect part. There is an inner hard plastic hose surrounded by the softer rubber hose. The inner hose appears to be shrink wrapped on the 90 degree elbow. We ended up at the junk yard, picked up two hoses. Only one worked. Evidently, not all 850s have the same type of fuel hose, or at least our R was different from the parts at the junk yard.

It pays to empty the tank first. We pumped the fuel out with a hand pump. Then lowered the fuel tank with the jack. We were able to get at the parts on the tank, while working under the car. It is only May, and about 96 degrees in the shade here in Texas. Working under the car was cooler than in the sun. We backed the car up on ramps to get better access. Hope this helps. Good luck fixing your hoses. I have one more 850 to do the exact same repair. If I think to do so, I'll post pictures.

Post by **phils94850** » 18 May 2010, 05:13

make sure you call your dealer and have them check your VIN. There was a recall on fuel tank leaks, i got my fuel tank and hoses replaced for FREE ...

TonysVolvoWagon · Post by **TonysVolvoWagon** » 18 Sep 2012, 20:55

I had a similar problem with the gas tank leaking when full. It turned out to be a two sided problem. First was the fuel pump gasket. It had been installed a little cockeyed and caused the majority of the leakage. There was also the small vapor that had been dry rotted. Pretty straight forward though as far as the tank removal went. Thanks for the help!

dasapir · Post by **dasapir** » 19 Sep 2012, 15:26

Well, I have been there twice now. About one month ago I had a code for large evap leak. Checked the system up front to the tank and noticed there was signs of gas from the top. So I used up what was left in the tank. Dropped the tank and found the crack in the new hose I had just replaced about 1.5 years ago. The same hose outdoor replaced. It was split completely through on the large end. I purchased another from the dealer. I completely checked the system and everything looked okay. No other cranks etc.
Truly difficult replacing the straps. In fact, I finally used long bolts to cinch up the tank and then one by one I traded them out for the original bolts once I had the straps close enough for the bolts to reach and be threaded.

Anyway, no codes, but now when I fill the tank topping it up I have a very pungent gas smell in the garage. Have not found the cause. Only when the gas level drops about two gallons does the small begin to wane. Any suggestions where else to look? the filter was change last year and the connection there is good. I did not see anything else on the top when the tank was down. And the pump looked okay.

Volvonick · Post by **Volvonick** » 01 Sep 2013, 18:44

Hey guys. I just bought my first Volvo. A 2000 S80 with 120xxx miles for $1300. I thought I was getting a pretty sweet deal considering the condition is pretty great and it has no mechanical issues. Other then the smell of gasoline in the car.

After I purchased it and got it home I changed the fuel filter thinking that was the problem. After I changed the filter I must have knocked the hose that was connected to the pump and made it leak even worse. I did some research and found out about the fuel pump recall. So I went ahead and took out the back seat and sure enough the pump is leaking. I am going to post some photos but I have a real question that hopefully someone knows the answer too.

Volvonick · Post by **Volvonick** » 01 Sep 2013, 18:51

So here is my question. I already ordered the fuel pump and I am just waiting on that to come in. My question is in the first photo. The gunk covered hole that I am assuming goes into that gas tank. When I lifted up the seats it was just as you see it in the photo. Should I plug this before I put it back together or is this a breather hole? Also if anyone has any tips or heads up before I remove the pump please let me know.

Post by **misha** » 01 Sep 2013, 21:58

It's your fuel pump housing that is leaking....not the fuel pump itself.The fuel pump housing needs to be replaced.
I have seen this on '01 V70...it had the same leak like you have.

Volvonick · Post by **Volvonick** » 01 Sep 2013, 22:09

So I just bought a fuel pump for nothing?

Gas Tank Removal Question + Leak photo

Re: Gas Tank Removal Question + Leak photo