1996 VOLVO 850 Fuel System, Gasoline Problems

I OWN A 1996 VOLVO 850 TURBO. RECENTLY THE GAS TANK BEGAN TO LEAK AT THE SEAM ON THE DRIVER SIDE NEXT TO EXHAUST HEAT SHIELD I CALLED VOLVO AND THEY TOLD ME THAT MY FOR MY VIN # THERE IS NO RECALL; ON THE INTERNET THERE IS A RECALL FOR THE SAME VEHICLE GAS STORAGE ISSUES. EXACTLY ON THE SAME SIDE SAME PROBLEM, BUT SINCE MY VIN # DOES NOT COINCIDE WITH THEIR RECALL, I HAVE TO PAY FOR IT. I DON'T THINK THAT IT IS FAIR, THAT JUST BECAUSE MY VIN # IS DIFFERENT FROM THE RECALL, NUMBERS, IT STILL HAS THE SAME PROBLEM AS THE MODELS THEY ARE RECALLING. IF THEY ARE RECALLING A CERTAIN MODEL IN THIS CASE THE 850 MODEL FOR SPECIFIC DEFECTS, WHAT DIFFERENCE DOES IT MAKE WHAT VIN # IT IS, IF IT HAS THE SAME PROBLEM ON THE RECALL. AND A SAFETY ISSUE. IF YOU CAN HELP WITH THIS, PLEASE LET ME KNOW WHAT I CAN DO. BECAUSE THE VOLVO AGENT WAS NOT VERY HELPFUL AND RUDE. BOTTOM LINE WAS TO BAD FOR YOU. *TR

Mileage: 170,000

> MY FAMILY RECEIVED A NOTICE FROM VOLVO CARS OF NORTH AMERICA, VIA US MAIL, DATED FEBRUARY 2005 > NOTICE EXPLAINS THAT: "IN CERTAIN CASES, AFTER PROLONGED EXPOSURE TO EXTREME HEAT, THE FUEL TANK IN MODEL YEAR 1994-1997 VOLVO 850 VEHICLES MAY DEVELOP SEEPAGE AT THE HEAT SHIELD ATTACHMENT. WHEN THIS OCCURS, A FUEL ODOR MAY BE PRESENT." >THIS IS A SERIOUS UNDERSTATEMENT AND, IN MY OPINION BASED ON MY FAMILY'S RECENT EXPERIENCE ON OUR VOLVO 850 LISTED ED IN THE RECALL, BORDERS ON CRIMINAL NEGLECT. > WE EXPERIENCED THIS PROBLEM WITH OUR OWN VOLVO 850 WITHIN THE LAST TWO WEEKS, AND IT WAS MUCH MORE THAN FUEL VAPOR. I WILL EXPLAIN: - A VERY STRONG INTERMITTENT FUEL ODOR BECAME NOTICEABLE, FOLLOWED SEVERAL DAYS LATER BY SEVER LEAKING FROM NEAR THE TOP OF THE GAS TANK DOWN ONTO THE CARS EXHAUST PIPE. I AM REALLY SURPRISED IT HAD NOT CAUGHT FIRE WHILE WE WERE DRIVING THE VEHICLE. - GAS WAS DRIPPING FROM THE TANK AT A RATE OF ONE DROP EVERY TWO TO THREE SECONDS. MY WIFE AND I NOTICED THIS AFTER A QUICK TRIP TO THE GROCERY STORE WHERE WE HAD PARKED ON LEVEL GROUND, ALLOWING THE GAS TO POOL UNDER THE CAR. - WE HAD TO CALL THE FIRE DEPARTMENT TO SECURE THE VEHICLE; THEY HAD EM MOVE THE CAR TO A SLOPED GRAVEL AREA TO KEEP THE GAS TO ONE SIDE OF THE TANK AND TO ABSORB THE DRIPPING GAS. > THE DEALER TOOK CARE OF THE PROBLEM IMMEDIATELY. THE POINT THAT I AM TRYING TO MAKE WITH ALL THIS IS THAT IF THE NOTICE HAD BEEN WORDED MORE STRONGLY AND INDICATING THE POTENTIAL SEVERITY OF THIS PROBLEM, WE WOULD HAVE HAD THE CAR IN A LOT SOONER. I'M JUST GLAD WE DIDN'T HAVE THE CAR PARKED IN A GARAGE ATTACHED TO OUR RESIDENCE. FEEL FREE TO GIVE ME A CALL OR E-MAIL AND I WILL BE GLAD TO FORWARD A COPY OF THIS NOTICE TO YOUR OFFICE FOR REVIEW. JOHN DOMINSKI FAIRFAX, VA. *JB

DT: CALLER RECEIVED A RECALL LETTER BUT THE CONSUMER FEELS THE DEALER DID NOT REPAIR THE PROBLEM. THE MANUFACTURERS RECALL #140 AND THE NHTSA RECALL #04V368000 WERE TO REPLACE A HEAT SHIELD. THE CALLER SAID SHE FEELS THE DEALER DID NOT DO THE RECALL BECAUSE AFTER THE REPAIR FUEL LEAKED WHEN SHE FILLED THE TANK. NEITHER THE DEALER NOR THE MANUFACTURER HAVE BEEN CONTACTED ABOUT THE PROBLEM. *NM

Mileage: 166,522

I OWN A 1996 VOLVO 850 GLT STATION WAGON WITH 72,500 MILES. THE FUEL TANK CRACKED AND DEVELOPED A LEAK FROM THE FOWARD HEAT SHIELD MOUNT ON THE GAS TANK. THERE WAS RAW GAS LEAKING 3 TO 4 INCHES FROM THE EXHAUST PIPE. THE CAR HAS NEVER BEEN IN A CRASH NOR HAVE WE HIT OR RUN OVER ANYTHING THAT DAMAGED THE GAS TANK OR HEAT SHIELD. I REPLACED THE GAS TANK AND SEALS AND HAVE THE OLD GAS TANK.*AK

Mileage: 72,420

I'M REPORTING THE FUEL TANK ON OUR 1996 VOLVO 850, VIN NO. [XXX], CALIF. LIC. [XXX], MILEAGE 93238. THE FUEL TANK STARTED LEAKING AROUND MARCH 27, 2004, UPON MY INVESTIGATION I OBSERVED FUEL LEAKING FROM THE LEFT SIDE OF THE FUEL TANK AT THE SEAM BEHIND THE EXHAUST HEATSHIELD. ON THE LEFT SIDE OF THE FUEL TANK THERE ARE THREE (3) SCREWS THAT FASTEN THE HEATSHIELD TO FUEL TANK. REMOVING THE TWO (2) OF THE SCREWS ALLOWED ME TO FURTHER OBSERVE FUEL LEAKING FROM MOLDED SCREW RETAINER. THE CAR HAS NOT BEEN DRIVEN DUE TO THE DANGERS ASSOCIATED WITH THIS LEAKING FUEL TANK. I FOUND ON THE NHTSA WEBSITE A PRELIMINARY EVALUATION (PE03-003) WAS OPENED IN JANUARY OF 2003 BUT CLOSED IN JUNE 2003. I ALSO FOUND AN ENGINEERING ANALYSIS (EA03-008) HAS BEEN OPENED AND THAT NHTSA HAS BEEN INVESTIGATING THIS MATTER AND HAS CORRESPONDENCE WITH VOLVO CONCERNING THE OTHER FIFTY FOUR (54) INCIDENCES. WE PURCHASED THIS VEHICLE NEW IN JUNE 1996, AND HAVE PROPERLY MAINTAINED THE VEHICLE AS SPECIFIED BY VOLVO. THIS CAR IS IN EXCELLENT CONDITION AND HAS NEVER BEEN IN AN ACCIDENT OR DAMAGED. PLEASE ADVISE WHAT SOLUTIONS OR REMEDIES THIS AGENCY OR VOLVO IS PLANNING OR DOING REGARDING THIS SERIOUS MATTER. UPDATED 07/30/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Mileage: 93,238

STEADY GAS LEAK FROM GASOLINE FUEL STORAGE TANK ON 1996 VOLVO 850 SEDAN. LEAK FROM TANK ITSELF CONFIRMED BY INDEPENDENT GARAGE WHO REGULARLY SERVICED THE CAR. AFTER I CONTACTED VOLVO U.S. (CUSTOMER CARE OFFICE), I CANCELLED A REPLACEMENT TANK THROUGH THE INDEPENDENT GARAGE AND TOOK THE CAR TO THE LOCAL VOLVO DEALERSHIP (ROYAL AUTOMOTIVE IN BIRMINGHAM, AL) FOR THE REPAIR. VOLVO HAS NOTIFIED ME THAT THEY WILL REPAIR/REPLACE THE TANK WITHOUT CHARGE TO ME BUT ONLY IF THE WORK IS DONE THROUGH THEIR DEALER. THE CAR IS CURRENTLY AT THE DEALER AWAITING INSPECTION BY THE VOLVO U.S. TECH FIELD REP. *JB

CONSUMER OWN A 1996 VOLVO 850 AND IT EXPERIENCED A SUBSTANTIAL GAS LEAK FROM HE GAS STORAGE TANK ITSELF. MR. JOHN ABBOTT ANSWERED BY PHONE. *PH *MR

GAS TANK LEAKS. *AK

FUEL SYSTEM, GASOLINE STORAGE SMELL OF FUEL FUMES PRESENT AT ALL TIMES WHILE OPERATING VEHICLE WHEN FILLING TANK, FUEL LEAKS FROM TOP OF FUEL TANK ASSEMBLY JUST AS TANK BECOMES COMPLETELY FULL. *JB

Mileage: 162,000

THE FUEL TANK SPLIT AT THE SEAM OVER THE EXHAUST PIPE. MANUFACTURER AND THE DEALER HAVE BEEN NOTIFIED OF THE PROBLEM. *AK

Mileage: 114,000

THE FUEL TANK LEAKED FUEL WHERE IT WAS BOLTED TO THE TANK. *AK *CB *NLM

Mileage: 68,352

WHEN FILLING FUEL TANK AT GAS STATION, JUST AS TANK IS NEARLY FULL, SEVERAL OUNCES OF FUEL LEAK FROM TOP OF TANK, DRIPPING UNDERNEATH CAR. *JB

WHILE DRIVING AT ANY SPEED SMELLED STRONG CHEMICAL FUMES IN PASSENGER COMPARTMEN DUE TO A DEFECT IN THE FUEL TANK. DEALER NOTIFIED. *AK

ON THE NIGHT OF MAY 13, 2003 A FEW HOURS AFTER PARKING THE CAR (1996 VOLVO 850) IN THE GARAGE THE SMELL OF GAS BECAME SO STRONG IT WAS OVERWHELMING. INSPECTION OF THE CAR AND FLOOR OF THE GARAGE REVEALED GAS LEAKING IN A FAST STEADY DRIP FROM THE FUEL TANK. THE LEAKED GAS HAD FORMED A SMALL PUDDLE ON THE FLOOR. ON THE MORNING OF MAY 14, I ARRANGED TO TAKE THE CAR IN FOR SERVICE WHERE IT WAS CONFIRMED THAT THE FUEL TANK WAS INDEED LEAKING FROM THE SEAM. THE CAR HAS NOT BEEN REPAIRED BECAUSE THE FUEL TANK WAS IS ON BACK ORDER AND IS NOT EXPECTED TO BE AVAILABLE UNTIL JUNE 1, 2001. THE CAR IS NOT DRIVABLE BECAUSE OF THE LEAKING FUEL. I BELIEVE THIS LEAK IS THE RESULT OF A DEFECT IN THE ORIGINAL FUEL TANK AS THERE IS NO APPARENT DAMAGE TO THE TANK. *NLM

I NOTICED AN ODD NOISE WHICH SOUNDED LIKE SOMETHING ROLLING AROUND IN THE BACK OF THE CAR, BUT NOTHING WAS. AT TIME OF STATE INSPECTION, I ALERTED THE INSPECTORS. THEY FELT SOMETHING BUMPING FROM WITHIN THE GAS TANK. I DISASSEMBLED THE FLOOR COVERINGS AND INSPECTION PORTS FOR FUEL PUMP AND GAUGE SENDER. I REMOVED THE GAUGE SENDER AND LOOKED INTO THE TANK AND OBSERVED A PLASTIC BOWL-LIKE OBJECT SURROUNDING THE FUEL PUMP. I ROCKED THE CAR AND THIS BOWL WOULD SLOSH AGAINST THE PUMP. THIS OBJECT APPEARS TO BE A BAFFLE TO REDUCE SLOSHING AROUND THE PUMP. IT WOULD SEEM THAT IT WAS INTENDED TO BE GLUED IN PLACE, BUT HAS BROKEN LOOSE. I SUPPOSE THAT THIS WOULD EVENTUALLY DAMAGE PUMP OR TANK. A NEW TANK WILL COST CLOSE TO $400 WHICH I WILL NOW ORDER. ADDITIONAL PROBLEM IS INTERMITTENT FAILURE OF ANTI-LOCK BRAKE/TRACS SYSTEM MODULE.*JB

Mileage: 97,000

CONSUMER STATED VEHICLE'S FUEL TANK HAS A LEAK AND IF FILLED OVER 12 GALLONS IT WILL LEAK FUEL, WHICH CAN RESULT IN A FIRE. DEALER NOTIFIED. TS *TT

Mileage: 80,000

UPON SMELLING GAS FUMES, CONSUMER INSPECTED VEHICLE AND DISCOVERED THAT THE FUEL TANK WAS LEAKING NEAR THE MUFFLER. DISCOVERED FUEL PUDDLE WHILE VEHICLE WAS PARKED IN DRIVEWAY. MR

THE FUEL TANK WAS OBSERVED TO BE LEAKING ON 7/8/02 AND THIS WAS CONFIRMED BY A TECHNICIAN ON 7/9/02. THE LEAKAGE OCCURS ON ONE OR MORE OF THE MOLDED BOSSES UPON WHICH THE HEAT SHIELD IS MOUNTED. MY SUSPICION IS BUILT-IN STRESSES FROM THE MOLDED BOSS, PERHAPS NOT RADIUSED PROPERLY WHERE THE BOSS JOINS THE TANK WALL. IT MAY ALSO BE A MATERIALS PROBLEM. THE TECHNICIAN ANALYZING THE PROBLEM SAID THAT THEY HAD SEEN THE SAME FAILURE ON ANOTHER 850 TANK WITHIN THE LAST 10 DAYS. IT IS ALSO POSSIBLE THAT OUR EXTREME AMBIENT HEAT MAY HAVE CAUSED A RELATIVELY INFLEXIBLE HEAT SHIELD TO STRESS THE ASSEMBLY. IT SEEMS TO BE A CRITICAL SAFETY PROBLEM, AND I AM DISAPPOINTED THAT VOLVO HAS NOT BEEN WILLING TO JOIN IN REMEDYING THIS SITUATION WITH US, AFTER CALLING IT TO THEIR ATTENTION.*AK

FUEL TANK DEVELOPED LEAK THROUGH RUBBING PARTS. *AK

GAS TANK WAS FAULTY OF LEAKING GAS. IT HAS BEEN REPAIRED. SMELL OVERWHELMING. DEALER DETERMINED IT WAS FAULTY.*AK

CASING TO THE FUEL TANK WAS INSTALLED IMPROPERLY AND CAUSED FUEL LEAKAGE. DEALER AND MANUFACTURER HAS BEEN NOTIFIED.*AK ALTHOUGH ITS A DEFECT VOLVO INSIST BECAUSE VEHICLE IS NO LONGER UNDER WARRANTYS. THE DEFECT HAD A T.S.B ISSUED AND VEHCILE WAS NEVER CHECKED. *YH

UNDER NORMAL DRIVING CONDITIONS STARTED SMELLING FUEL INSIDE THE CAR. IT WAS DETERMINED TO BE A LEAK IN THE FUEL TANK. IT WAS LEAKING FROM THE SEAM OF THE FUEL TANK WHICH IS PLASTIC. THE LOCATION OF THE LEAK WAS NEXT TO WERE THE EXHAUST PIPE RUNS. THIS, IN MY OPINION, COULD HAVE RESULTED IN A FIRE OR EXPLOSION. I FEEL LUCKY. WHEN THE FUEL TANK WAS REPLACED I DISCOVERED IT WAS REDESIGNED, THUS LEADING ME TO BELIEVE THIS WAS A KNOW PROBLEM TO VOLVO. I WAS ALSO REQUIRED TO REPLACE THE LEVEL SENSOR BECAUSE IT WAS NOT COMPATABLE WITH THE NEW DESIGN. I AM ALSO GOING TO BE CONTACTING VOLVO ABOUT THIS SITUTATION.

CONSUMER STATES THAT ABOUT (10) GALLONS OF GAS HAD LEAKED OUT FROM GAS TANK ONTO THE GARAGE FLOOR. *AK