98 V70 AWD leak on top of fuel tank

Post by **abscate** » 24 Jun 2013, 04:23

For a high pressure fuel Line the decision to replace with the correct part is correct IMHO .

Post by **holler1** » 24 Jun 2013, 07:18

I know there are lots of threads on the AWD fuel pump access, but for the sake of completeness, I'm posting a few more pictures. I forgot that the app loads the photos in reverse order. There is one showing the access ports inside the car to the filter and the lines. The second shows the pressure line from the filter and the return line from up front going up over the fuel tank - look at that one sideways. The line from the pump to filter is not there in this photo - I took it off. I'm pretty sure the line on the driver's side (at top in the picture) is the pressure line from the filter to the engine - can someone verify that? That line has some small rusty spots, but looks pretty good to me. The third one shows shows the "flap" and the pump top and the fourth how I did the hole cut with a drill and small hacksaw. The top of the pump is kinda rusty but dry. I'm not replacing the pump now, but I have easy access if it goes bad in future.

Post by **abscate** » 24 Jun 2013, 09:08

Keep a close eye on the condition of your exhaust system - unless you do a really good seal, that flap will be a potential inlet for exhaust gasses. If it is in good shape, no worries.

Post by **holler1** » 25 Jun 2013, 07:25

abscate wrote:Keep a close eye on the condition of your exhaust system - unless you do a really good seal, that flap will be a potential inlet for exhaust gasses. If it is in good shape, no worries.

Thanks, abscate. I plan to attach some metal trim around the flap with pop rivets so it overlaps the surrounding seat base area, and attach the trim to the surround either with rivets or bolts, with RTV between the trim and the surround to seal it. I'm going to wait til after I get the fuel line fixed to do this, so as not to flex the uncut top of the flap more than necessary.

Another issue. While waiting for delivery of the high pressure pump to filter line, I'm trying to see if I can get the fuel tank lowered a little more to make it easier to get the hp line into the area over the tank. I took the bolts out of the trailing arm and that lowered a bit, but could not get the arm off completely because it is blocked by the large jacking cylinder underneath it. I don't see how to take off the jacking cylinder because it has a hard brake line attached. The brake line actually goes through the top of that jacking unit. I'm worried about wrecking the brake line if I take the big bolt all the way out. What is the best way to do this?

Post by **holler1** » 03 Jul 2013, 07:39

Just to wrap up this thread, I finished installing a new fuel pressure pipe between the fuel pump and filter yesterday. I got the pipe from jimellisvolvoparts. It took a couple of weeks for delivery. jimellis has all the parts diagrams on their site, which is very useful in identifying parts. That fixed my fuel leak, so the car is running again. It was a little hassle getting the pipe into place, but I got it in by shoving it in back to front through the opening below the fuel pump wiring package. I also had to use straps to secure the small sensor near the filter (photo). This picture shows the new pipe and release valve near the filter. I'm attaching a photo of the new pipe; expensive at $97, but I wasn't confident I could fabricate one that would hold up. These pipes have flexible connectors with hard plastic inside soft rubber hoses- fairly complicated. I closed up the opening at the pump with aluminum strips and pop rivets, and RTV to seal it (photo). I think I can get it open again if needed by just drilling out the rivets. I had to drill and retap one of the tank strap nuts- they are 8mmx1.25 threads.

Thanks again to abscate and jimmy57 for advice.

Post by **abscate** » 03 Jul 2013, 16:05

I'm not getting the visual on this to understand the problem, sorry.

On edit ,..posted to wrong thread , please ignore

hollysugar · Post by **hollysugar** » 03 Jul 2013, 17:17

hello~

I have a similar problem with my 2000 V70R ... a fuel leak that seems to be coming from the top of the tank. I took it to a Volvo mechanic two days ago, he put it on the lift and found a loose connection around a hose that seemed to be the place from where gas was leaking. He tightened the connection, told me to drive it a couple days and see what happened.

By the time I got it home (30-40 mins) the gas smell was very strong, and when I looked at the tank, it had more raw gas on it, which now seemed to be coming from the top, rather than a side (the tank is only about 1/3 full).

In order to check for leaks or look at the fuel pump, the mechanic told me it would cost almost $800 in labour alone to get to the tank, since it is AWD.

Is there a way to access the tank without all that labour, and without cutting the floorboard? I don't know anything about cars, so I will need to take this to a mechanic, but I'd like to know what my options are beforehand. If there are links already on this forum to help me out, I'd appreciate being guided to where I can find them.

Some extra information:
I bought the car in March 2013, with 71,600 miles. Within a week or so of buying it, the ETS light has come on and off at seemingly random times. The acceleration of the car has been a bit erratic, sometimes the car shoots forward with just a little pressure on the gas pedal; other times it is slow and sluggish to pick up power (surging/hesitation).

I saw a website about the ETS/ETM problems that '97-2002 Volvos can experience: http://www.vexedvolvo.org/
Could this be related to causing a gas leak, or are they unrelated problems? Can I get the ETS problem be fixed under the recall, even though the 10-year period has expired? Seems with such low mileage on this vehicle, things like this should not be failing so soon (although I live in Hawaii, where the car has been since it was bought brand-new in 2000. I read that cars in hotter climates are prone to the ETM failure).

I don't have much money to spend on these problems right now, so I'm trying to find the easiest solution (obviously much harder to do since I don't work on cars, and I'm not very mechanically gifted!)

thank you for any help/advice!

Post by **holler1** » 03 Jul 2013, 18:19

hollysugar wrote:hello~

I have a similar problem with my 2000 V70R ... a fuel leak that seems to be coming from the top of the tank. I took it to a Volvo mechanic two days ago, he put it on the lift and found a loose connection around a hose that seemed to be the place from where gas was leaking. He tightened the connection, told me to drive it a couple days and see what happened.

Hard to tell what connection he tightened without more description of the location.

By the time I got it home (30-40 mins) the gas smell was very strong, and when I looked at the tank, it had more raw gas on it, which now seemed to be coming from the top, rather than a side (the tank is only about 1/3 full).

If the leak occurs only when the engine is running, I think that would be an indication the leak could be from the pump-to-filter pipe or hose (where mine was), or from the filter-to-engine pipe that crosses above the tank. That would tend to narrow down the leak location to the top of the passenger's side of the tank. The pipes on the other side are lower pressure.

In order to check for leaks or look at the fuel pump, the mechanic told me it would cost almost $800 in labour alone to get to the tank, since it is AWD.

He's probably quoting this based on taking loose the entire rear suspension, propshaft, exhaust system, etc and lowering the tank to the ground. I don't see that this is necessary based on my experience, and the comment by jimmy57 that I quoted on page 1. I would try to find a Volvo mechanic who understands how to lower the tank a few inches, enough to see the top of the tank with the engine running (again assuming it leaks only with engine running). That may be enough to see where the leak is coming from (as I did).

Is there a way to access the tank without all that labour, and without cutting the floorboard?

Cutting the floorboard is only needed if the pipe to the fuel pump needs to be removed, and may not be absolutely necessary.

I saw a website about the ETS/ETM problems that '97-2002 Volvos can experience: http://www.vexedvolvo.org/
Could this be related to causing a gas leak, or are they unrelated problems?

I don't know, but obviously finding and fixing the leak has to be high priority.

hollysugar · Post by **hollysugar** » 03 Jul 2013, 19:06

thank you holler1~

I will find more information and try to take some pictures, my descriptions of vehicle parts are rudimentary at best ...

I appreciate your comments!

Post by **cn90** » 04 Jul 2013, 06:41

Question fr the guru, I have the non-AWD (1998 S70 GLT), is this problem (fuel leak) unique to AWD model?