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Volvo S80 Fuel Leak

8 messages,  Last post on Jan 15, 2009 at 6:50 PM

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#1 of 8 Fuel leak, need to remove rear seat to investigate by mickjoebill Jan 09, 2009 (11:48 pm)
I love the S80 and this is my second. Car leaks when it is being filled at the pump. Leak comes from the top of the tank out of view from below the car. Otherwise no leaks. How do i remove the rear seat so I can access the removable cover in the floor?   Mickjoebill Replies to this message: JuaKali (Jan 10, 2009 11:13 pm) mickjoebill (Jan 12, 2009 7:53 am) JuaKali (Jan 12, 2009 7:53 pm)
#2 of 8 Re: Fuel leak, need to remove rear seat to investigate [mickjoebill] by JuaKali Jan 10, 2009 (11:13 pm)
Replying to: mickjoebill (Jan 09, 2009 11:48 pm) 1. Remove seat bottom by pulling it up at the front edge-(two clips), and swinging it upwards.   2. Remove sides of seat back-(closest to the doors) There are locking clips close to the bottom that need to be released. You have to pull open the lower portion of the side (about 6 inches from bottom from inner side with seat back folded down) to see the clips. Flashlight may be handy. You can use a screwdriver, or your fingers to release the clip that locks the side in place. Once released, pull upwards and remove. Repeat on other side.   3. With seat backs folded down, you should see electical connectors on both ends (closest to doors). Disconnect these. There are two 14mm bolts on either end. Remove these. Starting with left hand side seat back (shorter), lift edge closest to the door slightly so that alignment tab clears hole, and pull seat towards outside. There is a hinge in the middle. The left seat back has a hole that fits over a rod (part of right seat back). Remove right seat back likewise.   4. Remove any carpet or sound insulation, and you will see access port with four 10mm nuts on right side.   ******   I doubt his procedure will allow you to see source of a leak experienced during fueling. It will allow you access to the fuel pump and one of the two sending units. Replies to this message: mickjoebill (Jan 12, 2009 7:53 am) JuaKali (Jan 12, 2009 7:53 pm)
#3 of 8 Re: Fuel leak, need to remove rear seat to investigate [JuaKali] by mickjoebill Jan 12, 2009 (7:53 am)
Replying to: JuaKali (Jan 10, 2009 11:13 pm) Thanks!   I assumed that Ide be able to see the filler pipe entry form this port. I'll do more investigation before removing the seat. From what you say it sounds like I'll have to drop the tank to see the problem?   If i have to pull the tank out would it be a good idea to replace the fuel pump, car has done 86k kilos.   A side note, does the bottom part of the rear seat simply pullup? I've given it a hefty/tug /pull/ jolt from the font edge but haven't managed to unclip it. I can prise the rear part of the bottom seat from under the backrest but cant get the front part to budge...   cheers   Mickjoebill Replies to this message: JuaKali (Jan 12, 2009 7:53 pm)
#4 of 8 Re: Fuel leak, need to remove rear seat to investigate [mickjoebill] by JuaKali Jan 12, 2009 (7:53 pm)
Replying to: mickjoebill (Jan 12, 2009 7:53 am) The clips that hold the seat bottom in place are about a foot in from the edge (would be between your legs if seated) of the seat. If you lift the corner up and look (flash light) you should be able to see them. It takes a fair amount of force to disconnect them. Hold on to the seat on either side of the tabs (tab between) and yank straight up.   You may have a crack or fracture on one of the lines leading in/out of the tank - the supply and return lines connect to the pump here. This is not uncommon. I would recommend opening the port and observing the connections with the engine running or while cycling the ignition switch on-off-on-off this activates the pump each time you switch on. Outright pump failure is not very common. I have come across one at 146K MILES. Mostly the plastic connections at the tank (part of pump) break. If this occurs, you have to replace the pump unit - this also comprises a fuel level sending unit. It is quite expensive about $ 400 at dealers + a few $ for a new o-ring gasket and screw ring if you have to destroy to remove - (cheaper than buying $100 tool). Dropping the tank is a lot harder. Be carefull, keep all flame sources away Volvo flambe has serious side effects.   How much fuel is leaking?   Best of luck.
#5 of 8 only leaks whilst filling up... by mickjoebill Jan 12, 2009 (10:11 pm)
Fuel only leaks when we are at the petrol pump filling up. When we stop filling the flow of petrol onto ground stops. It is a considerable amount about half as much as the amount when pouring a cup of coffee!   Once port under seat is removes can we see the joint of fuel filler and tank? as it makes sense there is a break at this point   thanks!!   Mickjoebill
#6 of 8 by mickjoebill Jan 12, 2009 (11:23 pm)
The rate of flow is 1/2 that of typical coffee or tea pot.   Mickjoebill
#7 of 8 next question! by mickjoebill Jan 13, 2009 (8:27 am)
OK removed the seat and inspection covers. Unfortunately can't see the fuel filler line from these vantage points.   Next question, how is the fuel filler line attached to the tank?   Which side of the car does the filler hose meet the tank? Looks like the tank has to come out to refit the hose? How many hours work for this, could a non volvo garage do it? I have a RHD vehicle.   cheers   Mickjoebill Replies to this message: mickjoebill (Jan 15, 2009 6:50 pm)
#8 of 8 Leak found] by mickjoebill Jan 15, 2009 (6:50 pm)
Replying to: mickjoebill (Jan 13, 2009 8:27 am) Found the leak, it is in the joint of the filler hose and the tank.   Mickjoebill

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