1996 Volvo 960 Fuel system Problems

“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! …”

“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.”

“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. …”

“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 Inquired about parts to replace fuel rail ass'y for a 1996 Volvo 960, fuel rail ass'y has been superceded by a 1998 up design.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.”

“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. 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.”