Volvo 240/740/760/780/940/960 1990-1998

Tank Assembly

Print

On all vehicles, the fuel tank contains the fuel pump and sending unit assembly.

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. On the 2.9L 6-cylinder, as well as 2.3 and 2.4L 5-cylinder engine equipped vehicles:
    1. Tilt the rear seat forward and remove or fold back the trunk compartment carpet over the right-hand wheel well panel.
    2.  
    3. Disconnect the fuel pump electrical connections.
    4.  

  6.  

Take note of the color markings on the hoses; colored tape should identify hose locations on the pump.

  1. Detach the quick-connect couplers for the fuel delivery and return hoses.
  2.  

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Drain the fuel tank completely.
  4.  


CAUTION
When performing this procedure, always have a dry-chemical fire extinguisher handy. Fuel vapors are extremely explosive.

  1. In the trunk, remove the panels which cover the filler hose.
  2.  
  3. It may be necessary to remove the spare tire on some vehicles.
  4.  
  5. Roll back the carpet and remove the access panel cover.
  6.  
  7. Disconnect the fuel filler pipe connection. Remove the circlip retaining the fuel filler pipe (if equipped).
  8.  
  9. Label and disconnect all fuel lines leading to the fuel tank.
  10.  
  11. Label and remove all electrical connectors at the fuel tank.
  12.  
  13. On some models, it may be necessary to remove the driveshaft.
  14.  
  15. Position a floor jack under the tank, using a large piece of wood as a cushion between the fuel tank and the floor jack.
  16.  
  17. Raise the jack so that it just contacts the tank.
  18.  
  19. Remove any shields or protective covers on the tank.
  20.  
  21. Loosen and remove the tank retaining bolts.
  22.  
  23. Lower the jack slowly and inspect for any obstructions.
  24.  

To install:
  1. Install the protective shields and raise the fuel tank into position.
  2.  
  3. Install and tighten the attaching bolts.
  4.  
  5. Remove the floor jack.
  6.  
  7. Fasten the electrical connections, making sure that they are in the correct position.
  8.  
  9. Install the protective panel in the trunk, then replace the spare tire (as required) and the carpet.
  10.  
  11. Lower the vehicle.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Turn the ignition key ON and check for leaks.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the circlip on the fuel filer pipe to remove the pipe



Click image to see an enlarged view

Fig. Fig. 2: On rear drive models, the driveshaft must be removed



Click image to see an enlarged view

Fig. Fig. 3: Remove the tank-to-body attaching bolts



Click image to see an enlarged view

Fig. Fig. 4: Fuel tank assembly for a rear drive model



Click image to see an enlarged view

Fig. Fig. 5: Fuel tank assembly-850/C70/S70 and V70 non-AWD models



Click image to see an enlarged view

Fig. Fig. 6: If the tank is being replaced, remove and transfer the protective shield

 
label.common.footer.alt.autozoneLogo