Replacing the fuel tank

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Kristopher Shields
5 years ago
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1 Page 1 of 11 Replacing the fuel tank Special tools: Preparation Note! On cars up to chassis number the fuel filler pipe must be replaced when the fuel tank is replaced. Drain the fuel from the lines. See Draining the fuel system. Drain the fuel tank. See Draining the fuel tank. Removing the rear exhaust system Raise the car. both the rear wheels the front section of the exhaust system. Removing the heat deflector plate Remove the rear plastic nut from the lefthand wing liner. Drill out the pop rivets which hold the heat deflector plate at the rear subframe mounting and the exhaust system bracket. the plastic nuts holding the heat deflector plate the heat deflector plate. Exposing the fuel tank the plastic pipe with the largest connection to the carbon filter container. Position the pipe forwards towards the fuel tank the screws on the centre and left mountings of the heat deflector plate for the fuel tank the brake pipe from the clip in the front edge of the tank the fuel filter from the bracket the hose clamp from the fuel filler pipe and

2 Page 2 of 11 the hose clamp from the fuel filler pipe and the bleed pipe. Removing the brakes the mounting screws for the brake calliper. Hang the brake calliper in a suitable way the locating pins for the brake discs the brake discs. Hint: If necessary release the handbrake shoes. See Handbrake, brake shoes, replacing Removing the handbrake cable the return spring at the expander the expander. Lift the brake shoe slightly unhook the expander from the cable mounting. Remove the guide sleeve for the cable sleeve. Use a screwdriver. Pry carefully between the guide sleeve lug and the spindle. Remove the handbrake cable from the track rod and subframe. Bend the handbrake cables forward. Hang the handbrake cable from the front SIPS member. Lowering the fuel tank Position a lifting table under the fuel tank.

Page 3 of 11 Remove the tank retaining strap screws. Lower the fuel tank slightly. The ABS lines from the clips The fuel filler pipe and the bleed pipe from the fuel tank terminals.

3 Page 3 of 11 Remove the tank retaining strap screws. Lower the fuel tank slightly. The ABS lines from the clips The fuel filler pipe and the bleed pipe from the fuel tank terminals. Lower the fuel tank slightly further. fuel lines the plastic pipe between the carbon filter container and the evaporative emission system (EVAP) valve from the upper side of the tank. Lower the tank completely. Note! Check that the lines and wiring are unimpeded during the rest of the lowering of the tank. Applies only to cars with chassis numbers below Replace the fuel filler pipe. See Replacing the fuel filler pipe (When replacing the fuel tank). Transferring components Removing the fuel tank pressure valve Disconnect the hose (hose clamp). the screw the valve. Removing the splash guard pipe Remove the splash guard pipe. Pull straight out.

Take care with the fuel tank. Note! It is extremely important that the float arm is not broken or bent.

4 Page 4 of 11 Removing the level sensor Lift the left level sensor. the connector the ejector. Grip the righthand level sensor / pump. Pinch the float to hold it in its lowest position. Carefully and slowly pull up the holder. Carefully work the holder out. Pull the hoses and the wiring out of the tank. Note! Take care with the fuel tank. Note! It is extremely important that the float arm is not broken or bent. Removing the tank retaining strap and heat deflector plate the screws (x 2) the tank retaining strap the screws (x 2) the heat deflector plate. Installing the tank retaining strap and heat deflector plate the heat deflector plate the 2 screws. Tighten to 5 Nm the tank retaining strap the 2 screws. Tighten to 10 Nm.

5 Page 5 of 11 Installing the level sensor Install the sealing ring. Route the cable harness / hoses from the right level sensor to the left side of the tank as illustrated. Hint: Use a welding rod bent into a curve with a hook at one end to pull the cable harness / hoses to the correct position. Note! It is very important for installing the level sensor that the cable harness / hoses are routed into the front section of the fuel tank. Install on the lefthand side: sealing cover the ejector the connectors the level sensor. Tighten to 60 Nm. (Use special tool ). Note! Ensure that the arrow is opposite the marking on the tank. Install on the righthand side: the level sensor. Tighten to 60 Nm. (Use special tool ). Ensure that the arrow is opposite the marking on the tank.

6 Page 6 of 11 Installing the splash guard pipe Install the splash guard pipe. Note! Ensure that the locating pin is correctly positioned for the groove in the tank. Installing the fuel tank pressure valve the valve the screw the hose (hose clamp). Installing the fuel tank Position the fuel tank on the lifting table. Raise the fuel tank to a suitable height so that the fuel lines and plastic pipes between the carbon filter container and the evaporative emission system (EVAP) valve can be positioned in their terminals on the upper side of the fuel tank. Connect the fuel lines to the right level sensor / pump as illustrated. Route the electrical wiring to the passenger compartment through the floor.

Page 7 of 11 Lift the fuel tank up completely. Ensure that no lines or wiring are trapped.

Note! Always use new hose clamps. Install the ABS wiring in its clips. Tighten the tank retaining strap screws. Tighten to 25 Nm.

Installing the brakes the handbrake cable along the heat shields the screws in the centre and front mountings for the heat shield.

7 Page 7 of 11 Lift the fuel tank up completely. Ensure that no lines or wiring are trapped. Install the fuel filler pipe and the bleed pipe on the fuel tank at the same time. Twist the hose clamps so that they can be easily tightened later. Note! Always use new hose clamps. Install the ABS wiring in its clips. Tighten the tank retaining strap screws. Tighten to 25 Nm. Install the fuel filter and console. Tighten to 25 Nm. Installing the brakes the handbrake cable along the heat shields the screws in the centre and front mountings for the heat shield. the handbrake cables on the wheel units the handbrake cable mountings in the subframe. (25 Nm ) the mounting for the handbrake cable on the track rods. Press the guide sleeves for the handbrake cables into place on the wheel units. Hint: Lubricate the Orings on the guide sleeves. Use lubricant or silicon grease. the expander on the cable. Press the

Page 8 of 11 mounting together to lock the cable in the expander the expander between the brake shoes the return spring. Check the function. the brake disc and the locating pin.

See Handbrake, brake shoes, replacing Install the plastic pipe from the fuel tank with the large connector on the carbon filter container. Note!

8 Page 8 of 11 mounting together to lock the cable in the expander the expander between the brake shoes the return spring. Check the function. the brake disc and the locating pin. Tighten to 10 Nm the brake calliper. Use new screws. Tighten to 60 Nm. Note! If necessary, adjust the handbrake. See Handbrake, brake shoes, replacing Install the plastic pipe from the fuel tank with the large connector on the carbon filter container. Note! A click should be heard when the connector is pressed into place. Installing the heat deflector plate Position the heat deflector plate over the rear silencer. Install the plastic nuts and the rear pop rivet. Install the pop rivets on the rear mounting of the subframe. Install the rear wheels. See Installing wheels. Installing exhaust system Install the exhaust system. Use a new flange gasket. Tighten the screws. Tighten to 25 Nm.

9 Page 9 of 11 Finishing the 23 connectors on the right side and the 2 connectors on the left side the cover over the level sensors. Check that the wiring is correctly located in the groove in the rubber gaskets around the hole in the floor insulation panel the backrest. Replacing the carbon filter container Removing the heat deflector plate Remove the exhaust system (from the threeway catalytic converter (TWC) and downstream) as illustrated. Remove the left rear wheel. Remove the rear plastic nut from the plastic fender liner. Drill out the two blind rivets holding the heat deflector plate at the rear subframe mounting and the third rivet on the rear bracket for the exhaust system. Use a 5 mm drill bit Remove the plastic nuts and the heat deflector plate. Removing the carbon filter container

10 Page 10 of 11 Disconnect the thick plastic pipe. Press the pipe towards the carbon filter container. Press in the two catches. Disconnect the thin plastic pipe. Press in the catches. These are positioned forward towards the fuel tank. Pull off the pipe. Disconnect the plastic pipe from the clip. Remove the rubber hose from the carbon filter container and the tie strap. Remove the clamp holding the rubber hose (onboard vapor recovery (ORVR) fuel tanks only). Remove the shutoff valve from the bracket. Pull the shutoff valve straight up (ORVR fuel tanks only). Remove the two screws that secure the bracket. Pull the bracket and the carbon filter container down. Disconnect the carbon filter container from the bracket. Installing the carbon filter container Install the carbon filter container on the bracket. Tighten the screw. Tighten to 10 Nm. Place the bracket and carbon filter container against the subframe. (ORVR fuel tanks only) Press the shutoff valve into place on the bracket. Install a new hose clamp on the rubber hose. Install the rubber hose on the carbon filter container and the tie strap. Install the two screws that secure the bracket. Tighten to 25 Nm. Install the thin plastic pipe in the clip on the carbon filter container. A click should be heard. Installing the heat deflector plate Install the heat deflector plate and the plastic nuts the pop rivets. Install one rivet at the bracket for the exhaust system and two rivets on the rear mounting for the subframe the left rear wheel.

11 Page 11 of 11 Install the exhaust system. Use a new gasket. Tighten the nuts. Tighten to 25 Nm. Tighten the screws. Tighten to 25 Nm. Replacing the shutoff valve for the carbon filter container Replacing the shutoff valve for the carbon filter container Removing the shutoff valve Remove the carbon filter container according to Replacing the carbon filter container. Disconnect the connector, clamps and hoses from the EVAP canister shutoff valve. Remove the EVAP canister shutoff valve. Installing the shutoff valve Install the clamps and hoses on the shutoff valve. Check that the hoses are correctly positioned and are not twisted or kinked. Connect the connector. Press the quickrelease connector together until a clicking sound is heard. Install the carbon filter container according to Replacing the carbon filter container.

Installation instructions, accessories - Fuel driven heater 912-D

Installation instructions, accessories - Fuel driven heater 912-D XC90 Section Group Weight(Kg/Pounds) Year Month 8 87 2002 10 XC90 2003 D5244T, XC90 2004 D5244T, XC90 2005 D5244T AW50/51 AWD, XC90 2006 D5244T, XC90 2006 D5244T AW50/51 AWD D5244T R8703687 Page 1 of 20