Have a 1994 850 Turbo sedan.. When the tank is filled or topped off there , fuels leaks from fuel pump area or sender area. Does anyone have any experience with this? My fuel sender has metal cap and touches the frame on one side.. Tried tightening the large plastic screw on on top and it seems tight.. Had to remove one gallon of fuel to stop leak. Am trying to recreate the leak at this time.. Is there an easy way to remove the fuel lines to replace gaskets? Help!!

-- I think I have the problem under control---Time will tell--I am curious--The leak was on the fuel pump housing.. Repaired with epoxy-so far, so good..Passed my jack-up test. Wonder if doesn't hold, what is procedure and tricks for taking off the inlet and outlet hoses, if I have to replace the fuel pump?

Sounds like the $15 tank hose recall issue. Dealers quote $200 on it, so I knew it was a quick repair. Some say you should drop the tank a smidge, but I am not sure it is necessary, my kid did his hose on the 850 while I was distracted.

I am confused. The sender has a couple of wires coming out of it, the fuel pump has two gas lines coming out, one with yellow tape on it (never remove the yellow tape). Which one is leaking? Both of them have large rubber washers and O rings to keep the gas in the tank. Neither of them should be touching the frame of the car.

Klaus
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(V♂LV♂s 1995 854T, 1998 V70R)

On further exam , I have found a small crack on top of the fuel pump.Really small. I put a floor jack under the drivers side and jacked it up and put a couple of gallons of gas back in.. to simulate topping off at gas station. On looking very closly at sepage on top of fuel pump , found small crack,about 1/16 , cleaned it off with alcohol and dabbed epoxy on it because I don't have another fuel pump.Don't know if it will work or not! P.S. Already had it in for the recall and the heat shield is on the left or drivers side of the tank..Personally I think this is a hazard and Volvo should back it up!The dealer said cost for sensor would be about $200+ and fuel pump about $500.Will see if the epoxy stops the leak!! Really don't like to do this Mickey Mouse, but will check on new pumps tomorrow.. Any suggestions on removing the pump etc?

www.autohausaz.com has a fuel pump for $211.93, free shipping. The epoxy should work for a little while, unless gasoline will disolve it. Fortunately, it is not a hard part to replace.

Nice find :) I would never have thought of tipping the car to check for a leak. Even though not having a full tank will stop the leak, vapors will still leak out of the crack.

Klaus
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(V♂LV♂s 1995 854T, 1998 V70R)

Believe it's a gas tank issue. Check with your dealer...there was a recall on this and the symptoms were as you described them.
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1998 S70 T5 Emarald Green Metallic, 2004 V70 2.5T Ruby Red, Previous Owner of Black '94 850 Turbo Wagon. My cars have been running so well lately they've got me worried.