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Fuel Return Line Leaking

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

1975 - 1993 240
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1990 - 1998 960
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rmurphy7
Posts: 2
Joined: 24 November 2016
Year and Model: 1994 940 T
Location: Massachusetts

Fuel Return Line Leaking

Post by rmurphy7 »

The fuel sender on my '94 940 Turbo is leaking at the spot where the fuel return line enters the sender. Upon initial inspection from the little hatch in the trunk, I noticed the hose clamp holding it to the fitting was broken, but a replacement yielded no change to the slow leak. Investigating further, I pulled the hose off and put my finger over the hole leading into the tank: the leak slowed, but I could still see gas beading up under the fitting. This tipped me off that the problem might not be the hose or the hose clamp. At this point, I went under the car with a flashlight to get a better look. There, I saw a thick patch of rust at the point where the little metal fitting goes into the (plastic) cap. My theory now is that the fuel line is somehow rusting inside of the tank, and is allowing fuel to pass through the cap, or worse, has cracked the plastic. Has anyone ever had this happen? Any advice will be much appreciated!
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The hose on the right is the culprit I believe, although further inspection revealed that the hose may be the least of my problems...
The hose on the right is the culprit I believe, although further inspection revealed that the hose may be the least of my problems...

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