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Where to start

posted by  Oliver on  Wed Nov 25 01:08 CST 2009
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last visit: Tue Apr 24 15:09 CST 2012
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My 99 S70 AWD has an issue with fuel smells after filling up which is similar to the 96 850GLT I had. You can smell the fuel in the cabin and outside when the tank is full. Once the car has been driven to the point that the fuel needle just begins to fall - no smell at all.

This past weekend I filled up the S70 before traveling out of town on business. I was amazed when I got home four days later and could smell fuel up to ten feet away from the car. Never a leak on the drive way and fuel smell only when the tank is absolutely full.

I have looked under the car (no disassembly) and do not see any signs of fuel leakage on the filler hose or tank. I really would like to get this fixed, but would like some advice from the board as to the best place to start and what products can be used to seal the tank.

The 850GLT had a very similar issue and went to the dealer no less than ten times but the issue was never resolved. I would like to attempt this repair before I start that circus again.

Thank you in advance.

Oliver
Over a million Volvo Miles and still smiling:-)







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    Where to start

    posted by  jadnhm on  Wed Nov 25 02:01 CST 2009
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    last visit: Tue May 22 18:03 CST 2012
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    I have some bad news for you - working on the 'saddle' tank on the AWDs is a real PITA:
    http://www.brickboard.com/AWD/index.htm?id=1362154&show_all=1

    I think I read somewhere - maybe MVS - that there is sometimes a problem with the hose clamps on the fuel filler hose... you'll never get to it without either dropping the tank ($$$) or cutting holes (PITA again).

    I'd probably cut some well thought out access holes. By "well thought out" I mean, do your best to figure out the parts you're trying to access and where they are, and also keep 're-assembly' and sealing things back up in mind - any brackets or holders or anything like that will have to go back in it's exact same location when you're done, and any 'tubular' or 'structural' shapes might be dangerous to cut out. Also there will likely be either wiring or plumbing of some kind lurking directly behind the sheet metal so try to use the 'slow' cutting methods like chisels and snips as opposed to grinders, etc.

    I would recommend some serious digging before you start cutting holes or hand your car over to the $tealer.







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      Where to start

      posted by  jadnhm on  Wed Nov 25 02:13 CST 2009
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      last visit: Tue May 22 18:03 CST 2012
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      This is the thread I was talking about:
      http://www.matthewsvolvosite.com/forums/viewtopic.php?f=1&t=23851







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        Where to start

        posted by  Oliver on  Mon Nov 30 00:29 CST 2009
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        last visit: Tue Apr 24 15:09 CST 2012
        [RELATED]

        Thanks for the advice. I think I have one advantage as I removed the rear drive shaft due to VC issues and run the car as a front wheel drive, so tank removal may be a little easier. Filler hose and clamps is where I think I will start.

        Thanks again for the reply.

        Oliver

        Over a million Volvo miles and still smiling:-)








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          Where to start

          posted by  jadnhm on  Mon Nov 30 02:21 CST 2009
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          last visit: Tue May 22 18:03 CST 2012
          [RELATED]

          Unfortunately I don't think this will help you out. I have also done this AWD->FWD conversion and I know it doesn't make it any easier to get to the fuel tank in my car. The problem is the rear end drive and suspension assembly is all one piece (essentially) and bolted to the car 'through' the gas tank. You have to take the whole rear drive and suspension assembly off to get the tank down... total pain.

          I still think your best bet is to strip the interior out and try to figure out where you need to cut an access hole from above...







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