Gas leaking from top of new fuel pump. Yikes!

squiggy · Post by **squiggy** » 22 Dec 2009, 19:13

Hi guys. First post on this forum. My 1994 850 Turbo was running great and one day just wouldn't start. Someone told me to smack the bottom of the fuel tank with a hammer and see if the car started. That acutally worked once so we decided it was a bad fuel pump. Well, just finished replacing the fuel pump and the car runs great! Only problem is, gas is leaking from the fuel line connector at the top of the fuel pump. This was not a problem before installing the new pump. I am worried I wrenched on the connectors a bit too much or something? Seems like they pop off a bit easier now than the first time I tried to pop them off. Or... do you think the leak is happening because I do not have the metal cover bolted down over the top of the fuel pump (see photo)? Is one of the jobs of that cover to press the connectors down? That doesn't seem like its job but what do I know.

Thanks,
-squiggy

Post by **vegasjetskier** » 22 Dec 2009, 19:27

squiggy wrote:Is one of the jobs of that cover to press the connectors down?

No.

Check to be sure you don't have debris stuck in the fitting. And don't drive the car until you get the leak fixed.

Post by **confused_al** » 22 Dec 2009, 19:34

It has nothing to do with the cover. Two possibilities, first is that the metal tubes are somehow separated from the plastic base (not very likely). The second possibility is the connections from the fuel lines are went in all the way and seal them (more likely).
BTW, you did replace the rubber seal around the neck of the housing, right?

squiggy · Post by **squiggy** » 22 Dec 2009, 19:36

vegasjetskier wrote:
No.

Check to be sure you don't have debris stuck in the fitting. And don't drive the car until you get the leak fixed.

Thanks for the clarification about the metal cover. Concerning debris in the fitting, I have checked and checked and checked and I can't seem to detect anything wrong with it. I wonder (if need be) if I can buy new fittings from Volvo or somewhere. They just don't seem nearly as snug as the first time I tried to take them off. The first time I removed the left gas line fitting (with the yellow band) I noticed a tiny piece of red plastic or metal fall out. Apparently a piece from within the fitting. But upon inspecting the fitting and comparing it to the other fitting I cannot see anything missing or out of place. Sigh. What a drag.

squiggy · Post by **squiggy** » 22 Dec 2009, 19:41

confused_al wrote:It has nothing to do with the cover. Two possibilities, first is that the metal tubes are somehow separated from the plastic base (not very likely). The second possibility is the connections from the fuel lines are went in all the way and seal them (more likely).
BTW, you did replace the rubber seal around the neck of the housing, right?

Thanks. It might just be my imagination but the left gas line fitting (yellow band) does not seem to sit as low as the right fitting. I am very reluctant to force it down as I have applied a lot of pressure already and don't want to crack the plastic. There are no cracks or breaks in the plastic that I can see. Unfortunately, I did not install a new rubber seal. I will do this ASAP but I am nearly certain the leak is coming from that left gas line fitting. I can't see any obstructions inside the fitting or any reason why it would not seat all the way down or seal tightly. I've tried tapping it, pushing on it, twisting it gently from side to side to get it further down but it seems like it is as far down as it wants to go. Hmm.

Post by **confused_al** » 22 Dec 2009, 19:51

confused_al wrote:The second possibility is the connections from the fuel lines are went in all the way

What I meant was "not went in all the way.

squiggy wrote:but it seems like it is as far down as it wants to go

If I recall right, its like the spark plug wire goes in with a little "click" feel.

squiggy · Post by **squiggy** » 22 Dec 2009, 20:48

***PROBLEM FIXED***

This might be some kind of record for first time poster problem already resolved. lol. Hey thanks guys. Really. The left (yellow) fitting had a kind of green rubber 'spring' looking thing inside, just like the right fitting. But... for some reason the left fitting had a piece of green rubber down inside in a place that the right fitting did not. It looked legit, like it was supposed to be there but when I nudged it with a tiny flat head screw driver the little green piece moved. It was not attached to anything and had obviously broken off somehow and was now creating a blockage. A pair of tweezers dislodged the sucker. The fitting then slid all the way down and when I started the car no fuel leaked out. Awesome!!! I now have a great running car again after walking to work for... TWO MONTHS!!

squiggy · Post by **squiggy** » 22 Dec 2009, 21:05

Well... I spoke too soon.

Although the fitting now seats properly, I believe it is broken somehow and not sealing completely. I can see an occasional bubble appear at the base of the fitting and if I press the fitting down gently a trickle of gas leaks out which quickly becomes a puddle of gas. Apparently I was too hard on the fitting when I first popped it off and possibly damaged it. I guess I will start looking for a new fitting somewhere but I don't see any part like that on the Volvo parts sites I visit. Guess I may have to call the dealer. Sigh.

squiggy · Post by **squiggy** » 22 Dec 2009, 21:18

If just dawned on me that I might be able to grab a generic fuel line fitting at the local auto parts store and make it work. Does that sound like a good idea? Thanks.

Post by **confused_al** » 22 Dec 2009, 21:51

squiggy wrote:to grab a generic fuel line fitting at the local auto parts store and make it work

I dont see why not, but you need to be careful not to damage the metal tubes and the plastic base. Could That broken "green rubber spring" (I think it serves as the seal) replaced by another one?