Install:
− rubber seal on level sensor
− level sensor.

A2303465

26.

NOTE! Check the alignment of the level sensor
using illustration.

Install the nut finger tight. Check that the
position of the level sensor does not change.

A2303464

Page 12 of 16

27.

Installing nuts
Tighten:
− large nut to 40 Nm

30Nm

− small nut to 30 Nm.

40Nm

Check level transmitter wiring as illustrated.

A2300130

28.

Installing hoses
Reconnect hoses to fuel tank.
See illustration for correct location.
Tighten hose clamps to 3.5 Nm.
Turn spring clamps so that they do not rub
against the body or the tank..
Install rubber seal, P/N 6842188-2 on fuel
tank collar.
Lubricate inside of gasket and, if necessary,
lower end of filler pipe.
Important Ensure that the check valve (C) on the
end of the filler neck is in the correct position with
its locking tab on the filler pipe.

A23000182

Page 13 of 16

29.

Installing fuel filler pipe on tank 8631059
Install:
− filler pipe flange.
− screws. Tighten to 10 Nm.
− hose (1), with new clamp to the fitting
on the tank.
− cut the new hose (2), P/N 969106 to a
length of 450 mm.
− new hose (2) with new clamps.
A2303462

30.

Installing fuel filler pipe on tank 8676687
Install:
− filler pipe flange
− screws. Tighten to 10 Nm
− the fuel tank pressure sensor from the
old tank
− three joined hoses (1), P/N 9480050,
to the fittings. Secure the hoses
clamps. The narrower hose is for fuel
tank pressure sensor
− hose (2), with new clamp to the fitting
on the tank.
A2303466

31.

Installing fuel tank
Installing protective plates on tank install new
mounting straps (1) PN 9454593 and
9463196).

Page 14 of 16

32.

Installing fuel tank
Rest tank and tank band on jack.
Use same fixture and lifting table as when
removing tank.
Raise tank and tighten tank band at rear.

A2300145

33.

Installing fuel tank
Push tank forward as far as possible. Center
tank (see illustration) so that the level sensor
nut (white) does not contact the edge of the
opening.
Tighten front tank band bolt.
Press the clip with the fuel hoses into place
on the tank band.
Apply Underbody protection on exposed
body parts when needed.

A2300141

Page 15 of 16

34.

Installing rubber seals
Install filler housing around top of filler pipe.
Check that the inner rubber seal is correctly
seated and that the drain pipe is inside the
inner seal.
Check that Spring clip (1) is in position. Oil
mating surface on the rubber cover (2).
Install cover. Install the drain hose (3) last of
all, otherwise water or fuel will enter the
cargo compartment. Install the ring (4).
Install panels and carpets.

A2300147

35.

Verification of repair
Check that there are no leaks.
Check the function the fuel level sensor.

VOLVO for life,
Volvo Cars of North America, LLC
Technical Service

Please circulate, read and initial:

_____Svc Mgr _____ Parts Mgr _____Shop Foreman

_____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ TECHS

_____ _____ _____ _____ _____ Service Advisors _____ Warranty Administrator

Page 16 of 16

SUBJECT

Service Campaign 140: Inspecting the fuel tank and
installing rubber dampers MY 94-97 850, Excluding AWD
PARTS MGR

SERVICE MGR

NO

23

PAGE

MARKET

United States, Canada

COPY TO / CIRCULATIONS (PLEASE INITIAL)
GENERAL MGR

GROUP

SALES MGR

DATE

YEAR

MONTH

DAY

2005

02

08

140
1 of 3

Reference Bulletins: TNN 23 - 24A, SMB 23 - 140
This Service Campaign 140 involves MY 1994-1997 850 (excluding AWD), vehicles not previously covered
by Recall 139.
Volvo Cars of North America, LLC and Volvo and Volvo Cars of Canada Ltd. (Volvo) have decided that in
certain cases, after prolonged exposure to extreme heat, the fuel tank in all model year 1994-1997 Volvo 850
vehicles may develop a crack 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 and fuel
seepage is possible.
The corrective action will be to inspect the vehicle for fuel seepage or cracks at the heat shield attachment
points. The fuel tank will be replaced if any seepage or cracks are found. To prevent future occurrence of
fuel seepage or cracks, the corrective action will be to install a bushing to each of the heat shield attachments
on the fuel tank.
Number of Vehicles potentially affected in the Service Campaign 140, are approximately 121,300 in US and
approximately 20,700 in Canada. Please check QW90 for specific vehicle eligibility.
Note: Many of these vehicles will also be eligible for Recall 112 - Electric Seat Heater - Please take this
opportunity to complete any open Recalls on these vehicles. Inquire via VEN or VRC2 - Vehicle
Warranty where the message "RECALL 112 INCOMPLETE" will appear for eligible vehicles.

"Fixed Right — First Time"

Printed in USA on recycled paper containing a minimum of 50% wastepaper and 10% post-consumer waste.
© 2005 VOLVO CARS OF NORTH AMERICA, LLC

SUBJECT

NO

GROUP

Service Campaign 140

23

DATE

140

PAGE

2005-02-08

2 of 3

The following part numbers apply:
Part Number

Description

Qty

8629586
945407

Rubber damper
Flange nut

3 or 4 *
3 or 4 *

* See TNN 23-24A for details on require quantities per vehicle
An initial allocation of the rubber damper and flange nuts, representing 40% of the vehicles retailer at facility
will be made starting on or about the week of February 7th 2005. After this one time allocation you may order
additional quantities using normal ordering procedures. Note - Please set your DMS to "Manual Order" on
this part number so that you may monitor and limit your orders to actual demand.
A complete Vehicle Campaign List will be posted on VRC2 in the Reports Menu under Service Tab for 75
days from date of launch. This list details all affected vehicles that are on record as being retailed or currently
in stock at your facility. This report is only current at time of launch and vehicle eligibility must be confirmed
via VRC2.

Tank Replacement
If a fuel tank is required, and this should only be in rare occasions - refer to Volvo Vision under Parts inquiry
screen for parts released criteria. Replaced tanks will be required to be held for inspection by regional Volvo
representative. Please store and dispose fuel tanks according to your local state regulations.
The following part number apply depending on the vehicle emissions code (see TNN 23-24A and
SMB 23-140 for details)
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

*Only applies to M/Y 1994
Parts Bulletin

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

SUBJECT

NO

GROUP

Service Campaign 140

23

DATE

140

PAGE

2005-02-08

Cars with Emission code 3, 4
Material
Fuel tank
Gasket
Gasket
Nut
Nut
Gasket
Hose
Hose clamp
Tensioning band
Tensioning band
Protecting plate
All cars
Rust preventer/ Undercoating

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

0.1

Parts Bulletin

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

9510226

3 of 3

IMPORTANT CAMPAIGN NOTICE
[CAMPAIGN 140: INSPECTING THE FUEL TANK AND
INSTALLING RUBBER DAMPERS
SAMPLE OWNER NOTIFICATION LETTER
UNITED STATES]

February 2005

Dear Volvo Owner:

Your experience with your Volvo and the Volvo organization is very important to us. We
are committed to ongoing product improvements.
The reason for this campaign:
Volvo Cars of North America, LLC (Volvo) has determined that in certain cases, after
prolonged exposure to extreme heat, the fuel tank in model year 1994-1997 Volvo 850
vehicles 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.
Corrective Action:
Your Volvo retailer will inspect the vehicle's fuel tank for fuel seepage at the heat shield
attachment points. The fuel tank will be replaced if any seepage is found. To prevent
future occurrence of fuel seepage, your Volvo retailer will install a bushing to each of the
heat shield attachments on the fuel tank.
What you need to do:
Although your vehicle was neither originally sold in or currently registered in a state with
a hot climate, please call your authorized Volvo retailer as soon as possible to schedule an
appointment to obtain the corrective action. This procedure should take approximately
one hour. Due to service scheduling, your Volvo retailer may require your vehicle for a
longer period of time. We strongly urge you to have this service done.

If you previously paid to have your fuel tank repaired or replaced to address the problem
covered by this campaign, Volvo will honor your receipt with a refund. Please contact
your Volvo retailer for details.
Please contact:
If you have any questions, please contact your Volvo retailer. If your retailer is unable to
answer your questions, please contact Volvo Customer Care Center at 7 Volvo Drive,
Rockleigh, NJ 07647 or phone 1-800-458-1552, Monday through Friday, 8:30 A.M. to
7:00 P.M. Eastern Time. You may also e-mail us at [email protected].
Your continued satisfaction with your Volvo and the Volvo organization are very
important to us. We apologize for any inconvenience this may cause and we appreciate
your cooperation in arranging to have this important service completed as quickly as
possible.
Sincerely,
Eunice Stern
Manager, Customer Care
Please note: According to Insurance Institute for Highway Safety President Brian
O’Neill, it is very important that owners of vehicles in which problems have been
identified by the manufacturer take those vehicles back to dealerships as soon as they
receive notice of a service campaign. Such notices should not be ignored or taken lightly.