September, 2004
TO: ALL VOLVO RETAILERS – US
RE: RECALL CAMPAIGN 139: INSPECTING THE FUEL TANK AND INSTALLING RUBBER
DAMPERS
DESCRIPTION
Volvo Cars North America, LLC (Volvo) has decided that a defect related to motor vehicle safety exists in
certain model year 1994-1997 Volvo 850 vehicles.
In certain cases, after prolonged exposure to extreme heat, the fuel tank may develop seepage at the heat shield
attachment. This is because the heat shield attachment locations may not meet certain Volvo specifications.
When this occurs, a fuel odor may be present. Fuel seepage in the presence of an ignition source may result in
a fire.
The corrective action will be to inspect the vehicle's fuel tank for fuel seepage or cracks at the heat shield
attachment points. The fuel tank will be replaced if any seepage or a crack is found. To prevent future
occurrence of fuel seepage, the corrective action will be to install a bushing to each of the heat shield
attachments on the fuel tank.
The ONLY vehicles involved in this recall are MY1994 through MY1997 850 vehicles currently registered in
the following seventeen states: California, Arizona, New Mexico, Texas, Louisiana, Mississippi, Alabama,
Georgia, South Carolina, Florida, North Carolina, Tennessee, Arkansas, Oklahoma, Utah, Nevada and Hawaii.
Information on vehicles in the remaining states and Canada will be distributed in the near future, where Volvo
will implement this repair as a Service Campaign.
Number of Vehicles potentially affected in US for Recall Campaign 139 are approximately 78,000 vehicles.
Vehicle eligibility must be confirmed using VEN or VRC2 prior to performing this campaign.
OWNER NOTIFICATION
Note: There will be a staggered launch of customer notification letters between 09/24/04 and approximately
10/29/04. Please see the detailed customer notification launch schedule information for the 17 affected states in
the Parts Bulletin No Group 23-139.
RETAILER RESPONSIBILITIES
Retailers must perform this recall on eligible vehicles regardless of miles/kilometers or vehicle age. All work
performed under this Recall Campaign is free of charge to the owner.
In the event that a customer does not have a notification letter, the owner is not to be refused this important
recall work. Your regional representative will follow up to ensure that this recall is proceeding smoothly.
A complete description of the recall requirements and claim submission procedures will follow.
It is the retailer’s responsibility to review the details provided in the materials listed below with all involved
personnel.
•
•
•

Service Manager Bulletin 23-139
TNN 23-24
Parts Bulletin 23-139

•

Owner Notification Letter

Your cooperation in completing this important recall is greatly appreciated.
Drive Safely,
Volvo Cars of North America, LLC

VOLVO CARS

SERVICE AND PARTS BUSINESS

Service Manager Bulletin
TITLE:

Inspecting the Fuel Tank and Installing Rubber Dampers,
1994-1997 850
GROUP:

NO:

ISSUING DEPARTMENT:

CAR MARKET:

23

139

Warranty

United States

REFERENCE BULLETINS:

PB 23-139, TNN 23-24
Service Personnel:
Read and initial

SERVICE
MANAGER

SERVICE
WRITER

ISSUE DATE:

STATUS DATE:

2004-09-23

2015-12-10

WARRANTY
ADMINISTRATOR

Page 1 of 5
“Right first time in Time”

UPDATE NOTES: In Section “I,” revised Labor Operation and Labor Time.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.

RECALL CAMPAIGN 139 DESCRIPTION
VEHICLES INVOLVED
PARTS INFORMATION/PARTS RETURN
OWNER NOTIFICATION
VEHICLES IN RETAILER INVENTORY
RETAILER RESPONSIBILITY
CAMPAIGN REIMBURSEMENT PROCEDURES
TECHNICIAN COMPETENCY REQUIREMENT
RETAILER ALLOWANCE
CUSTOMER REIMBURSEMENT

A.

RECALL CAMPAIGN 139 DESCRIPTION
Volvo Cars of North America, LLC (Volvo) has determined that in certain MY 1994-97 850s may
have a defect in the fuel tank. In certain cases, after prolonged exposure to extreme heat, the fuel
tank may develop fuel seepage at the heat shield attachment. When this occurs, a fuel odor may
also be present.
The ONLY vehicles involved in this recall are MY1994 through MY1997 850 vehicles
currently registered in the following seventeen states: California, Arizona, New Mexico,
Texas, Louisiana, Mississippi, Alabama, Georgia, South Carolina, Florida, North Carolina,
Tennessee, Arkansas, Oklahoma, Utah, Nevada and Hawaii.
Information on vehicles in the remaining states and Canada will be distributed in the near future,
where Volvo will implement this repair as a Service Campaign.
Produced in the USA and available as an electronic document. Hard copy documents are printed in USA on recycled paper containing
a minimum of 50% wastepaper and 10% post-consumer waste.
© 2015 VOLVO CARS OF NORTH AMERICA, LLC

Service Manager Bulletin 23-139
Note: This will be a staggered launch of customer notification letters between 9/24/04 and
10/29/04. Please see customer notification launch schedule information for the 17 affected
states in this bulletin.
The corrective action will be to inspect the fuel tank for seepage or cracks at the heat shield
attachment points. To prevent possible further occurrence of fuel seepage, a bushing will be
installed to each of the heat shield attachment points on the fuel tank. The bushing will alleviate
any further stress on the attachment points. In the rare case that fuel seepage or cracks are found,
the fuel tank will be replaced. Recall 139 affects approximately 78,000 vehicles in the U.S.
B.

VEHICLES INVOLVED
NOTE:

RETAILER MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO
BEGINNING REPAIR FOR THIS CAMPAIGN.

Vehicle eligibility should be confirmed:
• Inquire via VEN or VRC2 - Vehicle Warranty where the message “RECALL CAMPAIGN 139
INCOMPLETE” will appear for eligible vehicles.
All vehicles should be checked for any other incomplete recalls or service campaigns or
service upgrades. All open Recall or Service Campaign or Service Upgrade repairs should be
completed.
RETAILER VEHICLE CAMPAIGN LIST
A “Retailer Campaign List” will be posted on VRC2 in the Reports Menu under the Service Tab for
75 days from initial launch. This list details all affected vehicles that are on record as being retailed
or currently in stock at your facility, and is updated monthly. Vehicle eligibility must be confirmed
via VRC2 prior to performing this recall.
C.

PARTS INFORMATION / PARTS RETURN
Please refer to Parts Bulletin 23-139.
PARTS RETURN
Replaced fuel tanks will be required to be held for inspection. Fuel Tanks should be stored and
disposed of properly per your local and state requirements.

D.

OWNER NOTIFICATION
Customer Notification Launch Schedule
Stage I
Approximately 10,000 customer letters, split between the following states that the vehicle was
originally retailed, will be mailed on 9/24/04.
Alabama
Arkansas
Mississippi
New Mexico
Utah
Arizona
Louisiana
Nevada
South Carolina

Page 2 of 5

2015-12-10

Service Manager Bulletin 23-139
Stage II
Approximately 30,000 customer letters, divided between the following states, will be mailed on
10/22/04. Approximately 50% of customers in each of the below stage II states will be contacted.
Stage II parts allocation will be sent to the below states starting on or about the week of October
11th:
California
Georgia
North Carolina
Tennessee
Florida
Hawaii
Oklahoma
Texas
Stage III
Approximately 38,000 remaining customer letters, divided between the following states, will be
sent on 10/29/04. The remaining 50% of customers will be contacted in each of the below states.
Stage III parts allocation will be sent to the following states starting on or about the week of
October 18th:
California
Georgia
North Carolina
Tennessee
Florida
Hawaii
Oklahoma
Texas
E.

VEHICLES IN RETAILER INVENTORY
All vehicles in retailer’s inventory and qualifying for this Recall Campaign should be repaired prior
to a customer taking possession of the vehicle.

F.

RETAILER RESPONSIBILITY
Retailers are to perform this campaign on eligible vehicles regardless of Mileage/kilometers or
vehicle age. The campaign work covered under Recall 139 is free of charge to the owner. In the
event that the original announcement letter is lost or misplaced, the owner is not to be refused
this important campaign work. Your Regional Representative will follow up to ensure that this
campaign is proceeding smoothly.

G.

CAMPAIGN REIMBURSEMENT PROCEDURES
All claims should be submitted using the LONG FORM application.

H.

TECHNICIAN COMPETENCY REQUIREMENT
The technician competency requirement for this campaign repair is: Level 2.

I.

RETAILER ALLOWANCE (LONG FORM APPLICATION)
INSPECTION AND REPLACEMENT OF BUSHINGS
Part Number
8629586
945407

Description
Rubber damper
Flange nut

Qty
3 or 4*
3 or 4*

* Four Rubber Dampers and Flange Nuts required when the fuel tank has a rear protective plate.

2015-12-10

Page 3 of 5

Service Manager Bulletin 23-139
Claim Type:
Main Operation Number:
Failed Part Number:
Cause Code:
Symptom Code:

S24048
90070 (Fuel Tank Check)
8629586
16
5E

Claimed Operation Numbers
Operation Number
90070
90106

Description
Fuel Tank Check
Rubber Cushions Install

Qty
1
1

Labor Time
0.1
0.3

REPLACING THE FUEL TANK (WHEN NECESSARY)
(LONG FORM APPLICATION)
Cars With Emission code 0, 1, 2, 5, 6
Material
Fuel tank
Gasket
Gasket
Nut
Nut
Fuel level sensor*
Hose clamp
Hose
Hose clamp
Gasket
Protecting plate*

Quantity
1
1
1
1
1
1
1
1
2
1
1

Part Number
8631059
9447141
9447142
3501322
9142607
9480918*
989879
969106
9142053
6842188
9470378*

Quantity
1
1
1
1
1
1
1
1
1
1
1

Part Number
8676687
9447141
9447142
3501322
9142607
6842188
9480050
989879
9454593
9463196
3531436

* Only applies to model year 1994
Cars With Emissions Code 3 or 4
Material
Fuel tank
Gasket
Gasket
Nut
Nut
Gasket
Hose
Hose clamp
Tensioning band
Tensioning band
Protecting plate
Page 4 of 5

2015-12-10

Service Manager Bulletin 23-139
Claim Type:
Main Operation Number:
Failed Part Number:
Cause Code:
Symptom Code:
Claimed Operation Numbers
Operation Number
23428
90070
90106
J.

S24048
23428
8631059 or 8676687
16
5E
Description
Replace Fuel Tank
Fuel Tank Check
Rubber Cushions Install

Qty
1
1
1

Labor Time
1.6
0.1
0.3

CUSTOMER REIMBURSEMENT
Please follow the instructions as outlined in the Warranty Policy and Procedures Manual
chapter 6, page 6.4.

2015-12-10

Page 5 of 5

Page 1 of 1
To read TJ
attachment
go to TIE

TIE - TJ

TIE - Technical Journal
Title

Recall Campaign 139

Ref No US16683.1.2 en-GB