Volvo 850 Made from 1993 to 1997, this Volvo line was available in both a wagon and a sedan, both with were graced with several trim levels.

850r fuel leak saga

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Old Sep 30, 2009 | 04:11 PM
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Default 850r fuel leak saga

So I've been struggling with solving a fuel leak issue. Basically whenever the tank was full, gas would leak out the top area of the tank ( a lot!).

My first thought was that since I replaced the pump a year ago, maybe the gasket was bad on the pump. Didn't fix it.

I also replied the supply and return lines to the pump, no go.

After some further troubleshooting, it turns out it's leaking higher on the tank, from a fitting next to the fuel sending unit. I went to the local dealer and they were kind enough to print out the parts page for my model and vin. According to the dealer, the part circled in the attached pic is not available separately. He suggesting getting some kind of two part epoxy.

Any other opinions on this?
 
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Old Sep 30, 2009 | 06:52 PM
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Are you sure it is not #23?
They commonly crack and leak fuel.

That is true that the one circled is not sold by itself.
 
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Old Sep 30, 2009 | 07:14 PM
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Well it could be. It is a blue fitting that is visible from certain angles from the fuel sending unit trap door (in from the cabin). I'm pretty sure the hose i'm looking at does not have a clamp on it though, as listed in the diagram for #23. From the picture, it looks like the clamp is a worm gear style. I suppose I could grab a picture of leaking fitting.

From my description, does it sound more like #23?
 
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Old Sep 30, 2009 | 07:27 PM
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My car has the same issue I believe. I need to drop the tank and make sure soon.
It is very common to see the rubber hose crack and leak.
I have one seen one tank leak at the Blue fitting.
 
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Old Sep 30, 2009 | 07:49 PM
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Interesting, thanks for the info.

Are you thinking the blue fitting is the #23 hose?
 
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Old Sep 30, 2009 | 08:01 PM
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No #23 is a rubber hose that is different sizes in each side.
But you can see it through the fuel pump access hole.
 
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Old Oct 10, 2009 | 06:15 PM
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So I dropped the tank today. #23 was the issue. The hose had a huge crank in it on the underside, right near the blue fitting. Also, it turns out I was looking at the wrong fitting. The blue fitting actually goes to #23. The circled hose is actually a gray fitting on the tank with some straight hose on it which goes to the filler assembly. I'll grab a picture of it tomorrow. It's super easy to drop the tank.

Disconnect the wires in the cabin, remove the straps and lower slowly with a trans jack of some sort. On mine, the entire filler pipping came out in with the tank, gas cap and all.
 
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Old Oct 10, 2009 | 06:27 PM
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Glad you are getting somewhere.
 
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Old Oct 11, 2009 | 09:07 AM
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Tech, is it a part of this recall?

http://www.autobuyguide.com/1995/12-...lls/index.html


JPN
 
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Old Oct 11, 2009 | 09:16 AM
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No it is not. It is only under the recall if the tank cracks at the heat shield mounting points. But also only if they find it doing the original recall to install the rubber mounts.
 
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Old Oct 11, 2009 | 09:41 AM
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I sucked.


JPN
 
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