Gas Tank Leak on 850

[alexk243]

OK so I pulled of the fuel level sender and it seemed to be find. Threw some silicon on it to be sure and put it back in. Lets see where it leaks now when I fill it up.

Also putting the tank straps back on really sucks... just though I would let you guys know lol

[alexk243]

Still appears to be leaking when I fill up the tank past 12 gallons.

Are these two parts at the very top of the tank? If so then they shouldn't be leaking when I have the car stationary (which it is, when filled over 12 gallons).

[JDS60R]

sounds like a fractured cover - replace the fuel level sender unit or fuel pump assembly as needed.

[byeboy]

Well, I'm following this. My 97 850 has a heavy gas smell if I put more than about 6 gallons in it, so I've been doing $20.00 at a time for many months now.
By reading other posts (like "I Smell Gas"), I had pretty much narrowed it down to the hose that runs across the top of the tank, which is apparently prone to splitting at the ends (like every other piece of rubber hose on this car!)..or to the Evap Check Valve...but I've kept myself busy doing a Valve Job, Replacing Motor Mounts, now have either a crank or cam seal (discovered while doing front motor mount) drooling, so I'll just keep my gas stops to $20.00 at a time in the meantime...just prioritizing month-to-month...I'll get to those fumes eventually...I did get a bit sidelined today to install a set of fender side blinkers (install was simple enough, but removing all the old adhesive from the "Volvo" emblem is proving to be a real tussle...I'll pick up a can of
solvent tomorrow...I've already tried, without success...Paint Thinner, Acetone, WD-40...

[cn90]

Can someone help me?

My 1998 S70 GLT with 160K has fuel leak at exactly where the filler pipe joins the gas tank.
Probably coming from above.

Below is Service Campaign 140 as Ozark Lee said (Thanks Lee!):
http://www-odi.nhtsa.dot.gov/acms/cs/ja ... 8-7750.pdf

I will call the dealer and ask if this is covered, but in case that does not work....

Below is the diagram for parts:
http://thevpstore.com/parts/1998/Volvo/ ... CallOut=17

#17 is 6842188, $12.50, but should I replace all 3 parts #16, #17, and #18?

[cn90]

This is a photo of my gas leak...1998 S70 GLT with 160K miles...

VolvoFuelTank01.JPG (122.28 KiB) Viewed 1297 times

[erikv11]

I am not experienced in fixing tank leaks, only know what I've read. But it seems pretty clear there is also a leak up top, not just at the filler neck. If you can take the car out of commission for a couple days, one way to know for sure is to drop the tank and inspect everything. From what I've read you can do many of the hose repairs up top without dropping the tank, but I've also read it isn't very difficult and that way you get a thorough look-over of everything.

[cn90]

Thanks erik,

I came across this post below (replacing the hose w/o dropping the gas tank). I will use this technique this weekend and post a DIY later. Laparoscopic fuel vent hose repair without dropping tank:

https://www.matthewsvolvosite.com/forums ... =1&t=54739

I have ordered these parts and will replace them all in one setting, as I hate to fix things in bits and pieces:

- PN 9463088 (#23 in the photo): Hose on top of gas tank ~ $18

- PN 6842188 Gasket ~ $11
- PN 9135119 Check Valve ~ $11
- PN 3531428 Clamp ~ $11

I will report back later...

FuelTankPN.JPG (133.98 KiB) Viewed 1290 times

[osman]

The "service campaign" only applies to later models even though earlier 850's have the same parts. I had this problem on an S80 once and the plastic stem which the rubber fuel line attaches to on top of the fuel pump had a crack that gas was shooting out of. I used JB waterweld and it fixed the problem permanently.

[KllewT5]

http://volvospeed.com/vs_forum/topic/14 ... -fix-pics/

My write up.