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P2 Fuel Sender Leak

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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ZionXIX
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Year and Model: 1996 850 Turbo S/W
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P2 Fuel Sender Leak

Post by ZionXIX »

Cross post from the XC90 forum. It's uh pretty quite over there. Anyway here's the situation.

"As part of my mini restoration I've been chasing a fuel tank leak. Ever since I replaced the fuel pump I have gas pooling on top of the fuel sender. Originally I did not change o-ring but since chasing the leak I have. I put a volvo brand o-ring, cleaned the sealing surface very well and greased the o-ring. I made sure the sending unit was seated all the way down before thread the lock ring. Arrow is pointed back and I've tightened the ring, a lot. After doing this job twice I went to fill up and noticed gas again but this time it coming from the top on the wired asymmetric raised plastic on top of the sending unit. Do I need to replace the sending unit at this point?"
20240322_192148.jpg
20240322_192148.jpg (384.8 KiB) Viewed 373 times
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20240322_192157.jpg (250.25 KiB) Viewed 373 times
Scarlett: 1996 850 Turbo Wagon in Reagent Red Pearl ~210K mi
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scot850
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Post by scot850 »

Looking at your picture above, if you look at the middle bottom of the picture on the raised portion, there is a crack in the casing. I would suggest this may well be the cause of your leak.

Neil.
2006 V70 2.5T AWD Polestar tune
2000 V70 R - still being an endless PITA
2006 XC70 - Our son now has this and still parked in our garage
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L - Sold
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - Sold

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