1992 240: gas fumes when tank is over 3/4 full. How to stop

Dana · Post by **Dana** » 22 Jan 2007, 08:43

I have a '92 240, and when you fill the tank past 3/4, there is a very strong gas fume in the cabin. Any ideas on what the problem is and how to remedy this?

thanks,
Dana

Post by **billofdurham** » 22 Jan 2007, 12:06

Welcome to Matthew's Volvo Site.

Usually it indicates a leak in the tank above the level you quote. As the fuel goes down past the 3/4 mark the smell will disappear because it is no longer leaking.

Petrol running down the sides of the tank will leave a mark which is usually easy to see. Have a good look with a high powered torch.

Bill.

Dana · Post by **Dana** » 22 Jan 2007, 12:43

Is the option here to replace the tank completely? or is there some method of repairing the tank? (don't laugh, i'm not too car savy!)

Post by **billofdurham** » 22 Jan 2007, 12:57

No laughing at this end. Have you found evidence of a leak?

In the UK it is possible to mend or have mended a fuel tank, subject to certain conditions about size of repair and general condition of the rest of the tank.

I don't know the legal position in the US so I can't answer that one but, if no-one else jumps in with the answer, I shall do some research.

Bill.

CarVolvo · Post by **CarVolvo** » 30 Jan 2007, 21:42

most of these cars leak on the top of the tank where road dirt accumulates and cause it to rust due to excessive moisture.

Procedure if your going to do it yourself is to drop the tank and use a special gas tank putty to seal it unless the leak happens to be on the seams of the tank. If its seams then it would most likely require a new one.

I have heard that radiator shops can fix gas tanks because it requires similar welding and coatings for repairs as rads.

Ofcourse if your going to work on it yourself.. always keep in mind.. open flames and sparks dont go. Its amazing how many stories you hear of people welding patches to repair gas tanks while the gasoline is still in the tank!!! Also i suggest you work in an open area where the fumes do not overwhelm you.

Kmaniac in California USA · Post by **Kmaniac in California USA** » 30 Jan 2007, 23:21

Here are a few comments from someone who has actually worked on and around the gas tank in his Volvo (1986 740 GLE).

Since the gas tank in my Volvo is PLASTIC and not metal, I would expect the same in your 1992 240. But that is my guess, I could be wrong.

The filler neck for the gas tank has rubber vent hoses attached that run between the filler neck and the tank. You should inspect these hoses first for deterioration and leaks before you blame the tank itself. Also inspect any other rubber vent hoses in the fuel system for leaks FIRST.

If you tank does have a leak and it is metal, DO NOT ATTEMPT TO WELD IT! Even if it has been emptied and let to dry, there is still enough residual fuel and vapor in the pores of the metal that the tank will explode like a bomb when a welding torch comes near. Only use a flameless patch on a a gas tank, like resin or epoxy.

Let us know what you find and what you do to fix it.

chester10 · Post by **chester10** » 31 Jan 2007, 01:22

Dana wrote:I have a '92 240, and when you fill the tank past 3/4, there is a very strong gas fume in the cabin. Any ideas on what the problem is and how to remedy this?

thanks,
Dana

Take it to a muffler shop for a free inspection.. there are lots of parts like Volvo muffler that you could find....it could be one of the gaskets between the pipe pieces has crumbled and letting out fumes before the tailpipe, so they roll up around the engine or mid-frame and you smell them with the air intake picking up the rising fumes.

CarVolvo · Post by **CarVolvo** » 31 Jan 2007, 09:57

The 6 volvo 240's ranging from 86 to 88 were not plastic..unless they are different in the USA?

wojeepster · Post by **wojeepster** » 02 Feb 2007, 18:12

might just be the oring gasket that seals the sending unit.

petershen1984 · Post by **petershen1984** » 03 Jun 2007, 00:33

I've just had a black rubber "neck" replaced that probably bridges the connection between the fuel cap and the tank itself... (1992 960). That might be a likely cause... I can smell gas vapor when the car is running. Yes, money being vaporized into the thin air...