EA03008 · EA
FUEL SYSTEM, GASOLINE:STORAGE Investigation
THIS ENGINEERING ANALYSIS WAS OPENED ON JUNE 11, 2003, BASED ON 54 REPORTS OF FUEL TANK LEAKS.THE SUBJECT VEHICLES WERE 1993 THROUGH 1996 MODEL YEAR (MY) 850 VEHICLES. MODEL 850 WAS ALSO PRODUCED IN MY 1997 AND WAS INCLUDED IN THIS INVESTIGATION. ANALYSIS OF THE DATA REVEALS TWO DISTINCT ISSUES. FIRST, THE 1994 THROUGH 1997 MY VEHICLES STAND OUT BY ACCOUNTING FOR 95 PERCENT OF THE REPORTED LEAKS.THESE VEHICLES SHARE THE SAME FUEL TANK DESIGN (PN 9142618). THE 1993 MY VEHICLE USES A DIFFERENT FUEL TANK DESIGN (PN 9141101).SECONDLY, THE FAILURES OCCURRED PREDOMINANTLY IN HOT CLIMATES, E.G., CALIFORNIA, ARIZONA, TEXAS, FLORIDA, GEORGIA, LOUISIANA, ETC.TESTING OF FUEL TANKS FROM CONSUMER VEHICLES AT THE VEHICLE RESEARCH AND TEST CENTER CONFIRMED LEAKS THROUGH CRACKS IN THE FUEL TANK WALL AT A HEAT SHIELD MOUNTING ATTACHMENT IN THE 1994 THROUGH 1997 MY FUEL TANKS (PN9142618). DETAILS OF THE TESTS ARE AVAILABLE IN TEST REPORT VRTC-DCD3060.VOLVO WILL CONDUCT A SAFETY RECALL ON ALL MY 1994 THROUGH 1997 VEHICLES ORIGINALLY SOLD OR REGISTERED IN THE FOLLOWING 17 HOT STATES: CA, AZ, NM, TX, LA, MS, AL, GA, SC, FL, NC, TN, AR, OK, UT, NV, AND HI.ALL 1994 THROUGH 1997 MY VEHICLES IN ALL OTHER STATES WILL BE REMEDIED UNDER A SERVICE CAMPAIGN.THE REMEDY FOR BOTH THE RECALL AND SERVICE CAMPAIGN IS TO INSTALL A NEW BUSHING AT EACH HEAT SHIELD ATTACHMENT POINT (3 PER TANK).ALSO, ALL TANKS (VEHICLES IN ALL STATES) WILL BE INSPECTED FOR FUEL SEEPAGE AT THE HEAT SHIELD ATTACHMENT POINTS AND VOLVO WILL REPLACE ANY TANK SHOWING SIGNS OF FUEL SEEPAGE.THE NEW BUSHINGS WILL PREVENT HEAT SHIELD STRESSES FROM BEING TRANSFERRED TO THE THREE HEAT SHIELD MOUNTING ATTACHMENTS ON THE FUEL TANK.THE SAFETY RECALL IS FILED UNDER NHTSA SAFETY RECALL NUMBER 04V368.THIS INVESTIGATION IS CLOSED.