1996 Volvo 960 Fuel system Problems

TL* THE CONTACT OWNS A 1996 VOLVO 960. THE CONTACT STATED THAT FUEL FUMES EMITTED INSIDE OF THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT FUEL WAS LEAKING FROM THE FUEL TANK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC. THE TECHNICIAN STATED THAT THE LEAK WAS FROM THE FUEL RAIL AND THE FUEL RAIL NEEDED TO BE REPLACED. THE VEHICLE AS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 73,000. UPDATED 09/10/15*LJ UPDATED 11/27/2017*CN

NHTSA ID

10734578

Incident

Jun 17, 2015

Mileage

73,000 mi

RAW GASOLINE LEAKING FROM MANUFACTURE DEFECTIVE FUEL RAIL. MANUFACTURE MACHINED SEALED TAPET/FLANGED ALUMINUM SEAL ON FUEL RAIL LEAKING RAW GASOLINE UNDER HIGH PRESSURE IN ENGINE BAY. PROBLEM ONLY OCCURS DURING ENGINE OPERATION. RAW GASOLINE IS FLAMMABLE. FUEL RAIL DELIVER SYSTEM PART OF EMISSIONS SYSTEM. OCCUPANTS MAY OR NOT NOTICE GASOLINE SMELL (NOXIOUS FUMES) DURING OPERATION INSIDE CABIN. MANUFACTURER RECALL ADVISED. *TR

NHTSA ID

10485136

Incident

Nov 15, 2012

RAW GASOLINE LEAKING FROM MANUFACTURE DEFECTIVE FUEL RAIL. MANUFACTURE MACHINED SEALED TAPET/FLANGED ALUMINUM SEAL ON FUEL RAIL LEAKING RAW GASOLINE UNDER HIGH PRESSURE IN ENGINE BAY. PROBLEM ONLY OCCURS DURING ENGINE OPERATION. RAW GASOLINE IS FLAMMABLE. FUEL RAIL DELIVER SYSTEM PART OF EMISSIONS SYSTEM. OCCUPANTS MAY OR NOT NOTICE GASOLINE SMELL (NOXIOUS FUMES) DURING OPERATION INSIDE CABIN. MANUFACTURER RECALL ADVISED. *TR

NHTSA ID

10479309

Incident

Oct 8, 2012

Mileage

166,800 mi

LEAKING FUEL RAIL - OUR 1996 VOLVO 960, WHICH WAS BOUGHT NEW AND SERVICED REGULARLY BY VOLVO MECHANICS, DEVELOPED A BAD FUEL ODOR INSIDE THE CABIN, AND, WHEN I OPENED THE HOOD, IT WAS APPARENT THAT IT HAD A SERIOUS GASOLINE LEAK, WHICH WAS MODE WORSE WHEN THE ENGINE WAS HOT. I TRIED TO FIND THE LEAK, BUT COULDN'T FIND ANY FUEL LINES LEAKING. WE TOOK IT TO OUR LOCAL VOLVO MECHANIC, AND HE SAID IT WAS THE FUEL RAIL, AND SAID THAT IT WAS QUITE COMMON ON THAT MODEL. I ASKED HIM IF IT WAS DANGEROUS, AND HE LOOKED AT ME LIKE I WAS A COMPLETE DUMMY! WE HAD THE FUEL RAIL REPLACED, AT GREAT EXPENSE, OF COURSE, BUT I COULDN'T HAVE MY FAMILY AT RISK DAILY IN THE CAR. THERE APPEARS NOT TO BE A RECALL, BUT I AM HAVING ONE OF THE LOCAL PERSONAL INJURY ATTORNEYS LOOK INTO THE SITUATION. SURELY THERE IS A BULLETIN OUT ON THIS DANGEROUS SITUATION! *LN

NHTSA ID

10378366

Incident

Jun 3, 2010

Mileage

136,511 mi

FOR THE PAST YEAR MY CAR HAS BEEN REEKING OF GASOLINE FUMES, NORMALLY IN THE MORNING WHEN COLD STARTING, BUT WOULD OCCUR PERIODICALLY THROUGHOUT THE DAY. THE SMELL WAS SO OVERWHELMING THAT I COULD NOT TURN THE HEATER ON IN THE CAR, AND WOULD HAVE TO PUT THE WINDOWS DOWN IN THE CAR WHILE DRIVING DOWN THE ROAD TO TRY TO RID THE CAR OF FUMES. I TOOK THE CAR TO THE VOLVO DEALER AND LEFT IT WITH THEM FOR DAYS. THEY ASSURED ME IT WAS A ACCUMULATION OF SOMETHING IN THE VENT SYSTEM, AND THEY CLEANED THAT OUT. THE PROBLEM STILL EXISTED. I FINALLY TOOK IT TO ANOTHER MECHANIC WHO FOUND THE PROBLEM. THE FUEL RAIL. THE END PIECE WOULD ALLOW FUEL TO VIRTUALLY SPILL OUT. PLEASE REFER TO THIS WEB SITE WHICH DESCRIBES THIS POTENTIALLY DANGEROUS SITUATION IN DETAIL: HTTP://WWW.VOLVOCLUB.ORG.UK/FAQ/960_90INFO.HTML#960B6300FUELRAILLEAKAGEPROBLEMS MY CAR WAS A POTENTIAL TIME BOMB. NOT ONLY DID VOLVO NOT FIND THE PROBLEM, BUT WHEN MY NEW MECHANIC FOUND THE PROBLEM IT TOOK MY MECHANIC THREE TRIPS TO VOLVO IN ORDER TO HAVE THEM ORDER THE CORRECT PARTS AS VOLVO NO LONGER MANUFACTURERS THAT PARTICULAR PART - HMMMM....I WONDER WHY. THIS COULD HAVE CAUSED A HORRIBLE SITUATION, ESPECIALLY WITH MY CHILDREN IN THE VEHICLE. WE EXPERIENCED SORE THROATS, AND FROZE TO DEATH ON COLD MORNINGS NOT BEING ABLE TO TURN THE HEATER ON DUE TO BEING FUMIGATED WITH GASOLINE FUMES. *NM *NM

NHTSA ID

10172972

Incident

Oct 16, 2006

Mileage

160,000 mi

THE FUEL RAIL BEGAN LEAKING FROM PLUG IN FRONT END OF RAIL. I WAS ABLE TO SMELL THE LEAK IN THE PASSENGER COMPARTMENT AND WAS ABLE TO AVOID A FIRE OR OTHER DAMAGE. LOCAL INDEPENDENT PARTS STORE INDICATED THAT THIS IS A COMMON PROBLEM WITH THE 960. BOUGHT A NEW, REDESIGNED FUEL RAIL FROM LOCAL VOLVO DEALER. IT WAS IN STOCK AND THEY INDICATED THAT THEY SELL A FAIR NUMBER OF THESE. THEY INDICATED THAT THERE IS NOT A RECALL ON THIS PART. THE NEW PART HAS A DIFFERENT DESIGN OF THE END PLUG WHICH LEAKED ON MY CAR. I NO LONGER HAVE THE OLD PART AVAILABLE. *JB

NHTSA ID

10144365

Incident

Nov 21, 2005

Mileage

139,420 mi

1996 VOLVO 960 SEDAN - FUEL RAIL LEAKAGE PROBLEM, FRONT OF FUEL RAIL DEVELOPED A LEAK AT A FACTORY PLUG (METAL). FUEL WAS POURING OUT BETWEEN METAL PLUG AND FUEL RAIL ONTO THE (HOT) ENGINE INTAKE MANIFOLD AND THERMOSTAT HOUSING. INQUIRED ABOUT PARTS TO REPLACE FUEL RAIL ASS'Y FOR A 1996 VOLVO 960, FUEL RAIL ASS'Y HAS BEEN SUPERCEDED BY A 1998 UP DESIGN. THIS IS A SERIOUS HAZARD WHICH COULD RESULT IN A FIRE AND POSSIBLE DEATH.

NHTSA ID

10129839

Incident

Jul 23, 2005

Mileage

97,398 mi

FUEL SMELL. *AK

NHTSA ID

10118108

Incident

Apr 16, 2005

Mileage

135,000 mi

THE CONSUMER STATED THAT THERE WAS A STRONG CHEMICAL FUME SMELL INSIDE THE PASSENGER CABIN COMING FROM THE ENGINE COMPARTMENT. THE DEALER STATED SORRY, NOTHING COULD BE DONE. THE VEHICLE WAS RUNNING WITHOUT WARRANTY. *AK THE FUEL RAIL ALUMINUM HOUSING WAS LEAKING WHERE IT WAS A CRIMPED TOGETHER AT THE ENDS. GAS WAS LEAKING WHEN THE VEHICLE WAS COLD AT THE FIREWALL AND GAS FUMES WERE ESCAPING THROUGH THE VENTS INSIDE THE VEHICLE. *SC

NHTSA ID

10029880

Incident

Jul 22, 2003

Mileage

69,051 mi

GAS TANK FAILED.

NHTSA ID

604870