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Old 07-30-2017, 10:24 PM   #1
LC4CARL
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Default Fuel leak on turn

'87 245.

Strong fuel smell after hard left turns. Pretty sure I'm getting fuel in the right "butt cheek." Filler tube union to tank looks ok. Tried a different filler cap. Visible in the filler when the flap is depressed is a clear plastic tube. Maybe to vent air while filling? Stumped.

Thx.
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Old 07-30-2017, 10:49 PM   #2
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Shouldn't this have a drain tube or something?


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Old 07-31-2017, 04:47 AM   #3
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There should be a hard plastic tube going to the hole through buttcheek.
Also check the o-ring on that filler cap, it may be dry cracked.
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Old 07-31-2017, 11:38 AM   #4
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Yeah. Mine suffers that every once in a while too. Check the cap seal for cracks/damage/wear, then make sure the filler neck is still round. Mine was slightly egg shaped and needed a very ginger manipulation to round out with a crescent wrench(be very careful and don't over torque, it can crack). I found a gas cap from a P2 car last week and the threads and sealing ring are a match. Haven't had any leaks since. As for that lovely bib around the filler, like petiww said, it needs a plastic tube, its routed down, inside the car and out the but check on that side.
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Old 07-31-2017, 12:02 PM   #5
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I think Billy Mays mentioned out-of-round fillers at one point. Now I understand.

The plastic tube just fits into the rubber "bib?" I'm thinking that I'd rather just have spilled fuel run down the exterior vs risk it leaking into the interior.

Be so nice to resolve this. Can't wait.
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Old 07-31-2017, 01:02 PM   #6
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The plastic tube fits into the rubber bib, then that flange on the bib is pressed through the sheet metal, creating a seal IIRC
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Old 07-31-2017, 10:35 PM   #7
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Thx.

The plastic tube inside the metal filler tube is supposed to be there? I ask as inside the car is another "vent tube" that appears to run externally from the tank to the upper portion of the metal filler tube.

Pretty sure the VW's don't have this problem, being air-cooled and all...
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Old 07-31-2017, 11:00 PM   #8
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OMG. Just took a good look at the fuel filler tube with the cap removed. It is no longer, uh, round...

I should be an auto tech.

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Old 08-01-2017, 12:30 AM   #9
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Old 08-01-2017, 02:53 PM   #10
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Tried to make the filler "round" with my Channel Locks. Ran her down to the roundabout. Fail! Epic fail...

Stupid car. Who in their right mind would fix up an import station wagon? I'm getting a Mustang...
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Old 08-01-2017, 11:35 PM   #11
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To replace the filler tube we: A) drop the tank and draw it down and out? or B) disconnect and take it out the gas door?

Thx.
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Old 08-01-2017, 11:48 PM   #12
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Read through this:

http://forums.turbobricks.com/showthread.php?t=269630

With pictures . . . .
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Old 08-02-2017, 12:09 AM   #13
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Awesome / thx! No Photobucket?

An alternative to the Mustang. I like it.
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Old 08-02-2017, 01:02 AM   #14
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Great tank thread. Love the 30* bend on the fuel pump.

Best I can tell, the Volvo filler is discontinued. Would be a bit of a crap shoot at the JY to find an unbent unit. Spent some time tweaking mine. Flipped the cap seal around in hopes of putting some new rubber on the neck surface. We'll see.
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Old 08-02-2017, 04:02 AM   #15
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Do not drop tank. Remove neck.

I commonly lower tanks and sneak in there to disconnect all sorts of things. It's commonly required as part of tank drops on modern cars.

Just a neck on these is a hose clamp.
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Old 08-02-2017, 07:33 AM   #16
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I just lowered the right side of the tank to replace my filler tube. I was brave because everything around the hose clamp was relatively clean because the fresh assembly. I probably wouldn't try it on a 30+ original assembly, but thats just me...

Also it is not that hard to remove the tank at all if its low on fuel.

Can you get somebody to lay in there and check where the fuel actually comes from?

Btw source that hard plastic tube there.
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Old 08-02-2017, 12:26 PM   #17
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Originally Posted by petiww View Post
Can you get somebody to lay in there and check where the fuel actually comes from?
I put a paper towel in the "bib" under the filler cap and it was soaked after my skid pad exercise. Pretty sure this is my leak.
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Old 08-02-2017, 12:30 PM   #18
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A crescent wrench works better for rounding the neck. I use a large crescent wrench at work all the time to unbend flanges on the Police Academy vehicles.
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Old 08-02-2017, 06:13 PM   #19
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Thx!
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Old 10-24-2017, 12:29 AM   #20
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Old 10-24-2017, 01:40 AM   #21
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I have same egg shaped filler tube, can't really do anything about it. However, I have brand new cap with new gasket, no smell on turn anymore.
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Old 10-24-2017, 01:46 AM   #22
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It's the little things that make Volvo ownership so rewarding.
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Old 10-24-2017, 01:55 AM   #23
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FORGOT TO MENTION. I had replaced at the same time fuel return hose. It was cracked near gastank.
After that and new cap with seal it stopped smelling like a fire hazard.

Start with that cheap and easiest option. Next would be sourcing filler tube. The small line you fixed/replaced is for overfilling protection.

Last edited by smeha; 10-24-2017 at 02:02 AM..
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Old 10-24-2017, 02:46 AM   #24
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I hate it when the Oregon gas monkeys slam the nozzle in there.



Here in Cali an ogged out filler tube will fail smog because the cap won't seal right.
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Old 10-24-2017, 03:23 AM   #25
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eee that one's pretty stretched. Some you can straighten, some are really badly stretched/deformed & oblong and the metal is too stretched to straighten by pinching. Have fun digging that out of the average Orie-gone gas station attendant JY 250-300K mile hoopt...

It's not too miserable, but it's in violation of 3 of my repair rules, and thus I'd avoid it like the plague;
1. Under the car.
2. Dirty.
3.Lots of a toxic liquid (coolant or gas) to potentially spill.
4. Heavy lifting/heavy work/actual effort/potential for injury or whatever physical malaise may be possible or probable.

Removal of the entire tank isn't required, but a TON of dirt sits on top of the tank from years of road use that will want to go everywhere as you try to disturb the band clamp, and you don't want dirt on the o-ring/in the tank when you replace it as petiww says.

But you took the greazy nasty mess of the engine (fluids, filth n' all) out and then did the heater fan second, this should be just the thing!

Try a better cap off an 850 or something first (easy), but if it's spilling out on turns, you probably need a new filler tube. Also check the evap hose on top of the filler tube just in case it's rotten or something (won't cause the exterior spill, but will cause a leak in the car).

Early cars and diesels don't have the problem so badly (steel on early cars), diesel doesn't have the narrow spout and the nozzles on diesel pumps aren't as thin and brutal. Diesel has no provisions for the evap system either though heh.
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