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DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

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
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

cn90
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DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by cn90 » Sun Nov 24, 2013 10:29 am

I have a fuel leak, which came from the top (EVAP hose, which was replaced), fuel was also dripping from where the gas tank and filler plastic pipe meets, not sure if it came from EVAP hose or the rubber gasket (that seals the gas tank and filler pipe). Since I plan to keep this car for another 5-7 years, I may as well take care of this issue. So I replaced the Rubber Seal at Gas Tank & Filler Pipe.

Any fuel leak is serious business, i.e., safety issue.

I could not find any DIY on the internet, so here you go.

I did not have much free time and had to fix this with about 12 gallons of fuel = not fun!!! It was a struggle with one floor jack, I had to use 2nd jack to help support the tank.

Best is to fix this when the gas tank has about 2-3 gallons, you don’t want an empty gas tank b/c of risk of damage to fuel pump. So 2-3 gallons is best.

Parts needed:
Gasket PN 6842188: $12.50
One-way Valve PN 9135119: $12.50



PROCEDURE
1. See the Fuel Leak:

Image


2. The clamps (3531428, qty = 2 per car) , I re-used them as they don’t look too bad.
VolvoFuelTank12.JPG
VolvoFuelTank13.JPG

3. Raise the RR tire side and set on jack stand, search forum for the proper locations. The 3-ton jack stand, even at its lowest setting worked fine for me.
Or drive RR tire on some wood ramps.


4. Open the gas door, remove the two (2) Torx screws. Look down and you will see the metal ring that keeps the rubber seal in place. This rubber seal is an integral part of the filler tube. Right behind it is another rubber seal that you can simply remove out of the groove.
VolvoFuelTank14.JPG

5. Go the trunk and d/c all electrical connectors. Use a small screwdriver to GENTLY pry the tabs to undo the connectors.
Also, remove the 10-mm bolts on the metal clamps. Note the clamp orientation for re-installation.
VolvoFuelTank15.JPG

6. The straps for gas tank: undo the two (2) 12-mm bolts, one toward the rear of the car and one near the exhaust. No need to undo any other bolts.
This is the problem when you have 12 gallons in the tank, is slides off the jack, it probably weighs some 80 lbs. Later I had to use another jack to lift it up.
BTW, use a piece of plywood and spread it the load to avoid damage to the gas tank.
VolvoFuelTank16.JPG

7. In order to d/c the filler pipe from the tank, you need to d/c all 3 fuel hoses as in the photo, there are 3 connections to undo. Note the hose #2 runs under the fuel pump hoses. You need to undo the plastic strap (press it down and slide it out of the slit) to free up the hoses so #2 can slide out.
NOTE: during install, make sure you put this strap back to hold down the fuel hoses.
VolvoFuelTank17.JPG

8. Note the orientation of the 1-way valve. The trick for the rubber seal: apply some fresh oil to ease insertion. Insert the rubber seal into the gas tank first but stop at about 80% in, leaving about 1 inch gap, i.e., don’t fully insert it. Now oil the filler pipe and insert it in.

Note: Don’t install the clamps until the very end, this way you allow the filler pipe to move a bit during installation. In other words, you want to avoid damage to the gas tank neck!
VolvoFuelTank18.JPG

17. NOTE: The “Service Campaign 39/40 thingy”: remove the heat shield, if there is no leak at the Torx screw site, add a rubber seal or plastic washer (to prevent future crack of the tank), the install the Torx screw gently (i.e., snug only), no need for force as this may break the screw area. If this break happens, you need a new (hopefully free) gas tank from Volvo.

Re-installation Note: go SLOW, watch the tank goes up (using floor jack), then go the trunk to check for the wiring, strap, connections (remember to re-connect the 3 hoses that you disconnected earlier!).

If you pay attention to detail, then this job should not take more than 2h.
Go to gas station and fill it up to make sure there is no leak.

Enjoy a leak-free tank = priceless!
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brunocerous


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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erikv11
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by erikv11 » Sun Nov 24, 2013 11:16 am

Nice write-up as usual!

Question:

You went through the trouble of drilling holes and replacing the fuel vent hose semi-blind (http://www.matthewsvolvosite.com/forums ... =1&t=60269), then literally a couple days later dropped the tank to do this job. And that exposes the leaky fuel vent hose (#2 in your pic) to make that job almost zero effort when done at the same time. Now that you've been through both jobs, would you say it is pretty easy to just drop the tank ("should take no more than 2 hours") and do everything at once?


'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

cn90
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by cn90 » Sun Nov 24, 2013 3:09 pm

The drilling hole business for the EVAP hose, I did that just to help those who want to replace ONLY the EVAP hose w/o dropping the gas tank.

I did that as a "proof of principle" only.
Last edited by cn90 on Sun Nov 24, 2013 7:01 pm, edited 1 time in total.


2004 V70 2.5T 100K+
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jreed
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by jreed » Sun Nov 24, 2013 6:01 pm

Great photos and description! Love it! Thank you!


1997 855 GLT (Light Pressure Turbo) still going strong. Previous: 1986 240 GL rusted out in '06, 1985 Saab 900T rusted out in '95, 1975 Saab 99 rusted out in '95, 1973 Saab 99 rusted out in '94

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rspi
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by rspi » Sun Nov 24, 2013 6:16 pm

I had to get a lot of fuel out of a tank not long ago. I disconnected the fuel filter and let the fuel pump, pump the gas into a container. Another option is to screw something on to the back of the fuel rail and let the pump push it out that way.

Thanks for the write up.


'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

cn90
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by cn90 » Sun Nov 24, 2013 7:02 pm

Another way to "dodge the bullet" is to fill the gas tank to only 3/4 full until you have time to fix these fuel leak issues.


2004 V70 2.5T 100K+
2005 XC90 2.5T 110K+

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rspi
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by rspi » Sun Nov 24, 2013 9:02 pm

My car is usually under 1/2 tank. Lol


'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by erikv11 » Sun Nov 24, 2013 9:12 pm

cn90 wrote:The drilling hole business for the EVAP hose, I did that just to help those who want to replace ONLY the EVAP hose w/o dropping the gas tank.

I did that as a "proof of principle" only.
OK, that makes sense, thanks. My 95 needs the fuel vent for sure, I think I will drop the tank and do all three. Order parts now, wait for a warm enough day when I have time do do the job ...


'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

flyazzbowtie
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Re: DIY: 1998 S70 Gasket at Gas Tank & Filler Pipe

Post by flyazzbowtie » Mon Mar 26, 2018 2:25 pm

The posts are helpful for me but I now just need to know what to do with the second line from the front of the car. It has nowhere to go back at the tank or lines. I don't get it. What am I not seeing?



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