Just check mine and did a preventive fix. Let me know if you think this is a good fix.

The ground strap kind of wraps around the aluminum pipe. The edge on the strap can ride up against the pipe which is probably a slow sawing action through vibrations.

I simply unbolted the ground strap from the body, unwrap it from the aluminum pipe and reconnected it to the body in the big empty space in front of the aluminum pipe. In this space, it might only rub up against the wheelwell. (Becareful not to drop your wrench or the bolt while working in there, not sure if it can be retrieved)

Would you consider this to be a good preventive fix?
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Volvo for Life

Add me to the list. The identical problem. Everyone kept telling me it was a poOrly seated gas cap. Anyhow...my car was covered by a used car warranty. It is 2001 T5 V70 5 speed. It took Performance Motoring in Hadley Mass a couple of weeks to get it done...starting with something they called "J tubes", and finally doing what the dealer had estimated as a $410 filler tube replacement.

I had suggested epoxy or silicone...but they didn't want to try. I had this done under the warranty at Performance Motoring, but it took some major whining. They claimed that they had $800 in the repair.

Other lesson learned...even if you communicate with the warranty provider within the mileage of the warranty and they pledge to fix it....don't go beyond the miles before dropping the car off for repair.

JF,

I can't believe I am reading this having just returned from the dealer for repair of the very same problem! It cost me $750 Canadian and Volvo would not honor the warranty because it had expired in Nov. 2004. The emmissions warning light and check engine light came on and it took three tries for the dealer to get it fixed. The first time, I had too much gas in the tank for the diagnostic test to run. The next time, the test pinpointed the problem but the dealer didn't have the part. This time, they charged me for not only fixing it but fot the two times before when they had run the test! I am contacting Volvo NA tomorrow because I am furious at the fact that this could even happen and that they wouldn't cover it despite my VERY low mileage (47,000 miles - the car was purchased in the US but is now driven in Canada). I should not have been charged for the number of times I had to bring it in - in fact, they should have paid me for my wasted time. Furthermore, when I arrived at the dealership today at 4:30 PM the car was not ready - they wanted to wash it. Half an hour later, I was still cooling my heels. When I had arrived at 5:20 PM the appointment before (where the problem had been diagnosed but there was no part), they were closing up and I was told "you're lucky, we're locking up."

I am seriously considering getting rid of the car because of the high maintenance involved and the lousy dealership with which I must deal. They are the only game in town and know it.

The dealer did a gas tank pressure test to find out I had a small hole in the aluminum pipe going from the fuel filler hole to the tank. This hole was caused by a ground strap grounding the pipe to the chassi. With vibration, the strap was rubbing on the pipe eventually damaging it slightly. Apparently, from what the mechanic told me, it is not the first time he saw this problem on the 2001 and up.

This needs to be reported to NHTSA and Volvo North America. Suggest you email both. A safety issue for sure!

Klaus
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98 V70Rawd(108Kmi), 95 854T(88K mi), 75 164E(173K mi)