Gas Tank Removal Question + Leak photo

I followed a link on volvospeed.com – – as a reference. Mine was a little different.

Gas Tank Removal & Leak Fix Tutorial

1. Disconnect the negative battery cable for safety.
2. Block the front wheels, jack up the rear, use some jack stands to hold up the rear.
3. Remove the floor board to open up the area to access the top of the fuel pump and sender.
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4. Unbolt the cover over the fuel pump and sender. Unhook the electrical connectors so they can go through the hole when dropping the tank.
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5. There is a circlip that holds the fuel filler in the door. Pop this out so you can lower the tank with the fuel filler. Just push out the rubber seal so it comes out of the fuel door hole.

6. Line up a floor jack to support the gas tank when you unbolt the supports. There are 3 bolts that hold up the metal band supports. Unbolt them and use your floor jack to slowly lower the tank while guiding the fuel filler tube as you slowly lower the tank. Move the metal bands out of the way and lower the tank. Make sure your electrical connectors come through the holes without getting hung up.
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7. With tank down, you should be able to slide the jack out and and replace the cracked hose under the car.
IMGP4197Large.JPG (51.22 KiB) Viewed 10058 timesIMGP4199Large.JPG (38.6 KiB) Viewed 10058 times8. The Cracked hose. It just poured fuel out when the tank got full.

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9. This is where I noticed my hose was different than the volvospeed.com post. I had a molded rubber hose that had ends with different sizes. I got some 3/4 inch fuel hose that would fit on the tank vent hole end. I cut out a good section of the original hose and slid the 3/4 hose over this, used a little JB Weld to seal the end, added a hose clamp and put ‘er back in place. So far this has worked. However I noticed I cannot use the fuel pump at full speed due to fuel backing up.
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10. After hooking up the hoses, get your tank back on the floor jack and begin the process of raising the tank. Make sure your jack is not in the way of the metal supports. Guide the filer hose back up to the filler door as you jack up the tank. As the tank gets higher, work the electrical connectors back through the hole.
I started the front bolt first and found that to be the best. Just get a few threads started on the front bolt and then work on getting the rear bolts. I found the passenger rear bolt the hardest FYI.