Tools and Materials Needed:
- New gas tank
- Fuel line disconnect tool
- Socket set
- Wrench set
- Flat-head screwdriver
- Replacement fuel filter
- Safety goggles
- Gloves
- Jack and jack stands (optional)
1. Safety Precautions:
- Ensure that the vehicle is parked on a level surface, turned off, and the parking brake is engaged.
- Disconnect the negative terminal of the battery to prevent any electrical accidents.
- Wear safety goggles and gloves to protect yourself from any potential spills or fumes.
2. Remove the Fuel Pump Assembly:
- Open the trunk of the vehicle.
- Locate the fuel pump assembly access panel. It is usually covered by a carpet or a panel.
- Remove the screws or bolts holding the access panel in place and set it aside.
- Disconnect the electrical connectors and fuel lines connected to the fuel pump assembly. Use a fuel line disconnect tool to release the fuel lines safely.
3. Support the Gas Tank:
- Place a jack and jack stands under the car to support it. Ensure the vehicle is stable before proceeding.
4. Disconnect the Fuel Lines:
- Locate the fuel lines connected to the gas tank. They are typically located near the front of the tank.
- Use a fuel line disconnect tool to carefully disconnect the fuel lines. Be prepared for a small amount of fuel to spill. Collect the spilled fuel in a suitable container.
5. Remove the Tank Straps:
- Locate the tank straps that hold the gas tank in place. There are usually two straps, one on each side of the tank.
- Use a wrench or socket set to loosen and remove the bolts holding the tank straps in place. Make sure to support the tank as you remove the straps.
6. Lower the Gas Tank:
- Carefully lower the gas tank by guiding it down. It might be necessary to maneuver it around components such as the exhaust system or suspension parts.
7. Install the New Gas Tank:
- Lift the new gas tank into position.
- Reinstall the tank straps and tighten the bolts securely.
8. Reconnect the Fuel Lines:
- Reconnect the fuel lines to the new gas tank. Make sure to reconnect them securely and check for any leaks.
9. Reinstall the Fuel Pump Assembly:
- Reinstall the fuel pump assembly and reconnect any electrical connectors or fuel lines that you disconnected earlier.
10. Tighten All Connections:
- Double-check all connections, especially the fuel lines, to ensure that they are tight and secure.
11. Reconnect the Battery:
- Reconnect the negative terminal of the battery.
12. Test the Fuel System:
- Turn on the ignition but don't start the engine. This will allow the fuel pump to prime the fuel system. Check for any leaks or unusual noises.
- If everything seems normal, start the engine and let it run for a few minutes to check if the fuel system is functioning correctly.
Note:
- If you notice any leaks or issues while replacing the gas tank, it is important to consult with a qualified mechanic or refer to a specific repair manual for your Volvo 240 model.
