I've looked at the posts in the FAQ about the fuel rail leakage problem on these cars. I can't tell if mine is the old or new type from the description. It is held to the cylinder head with two triangular brackets. There is a brownish stain around the front of the rail-but there was leakage from the oil filler cap gasket that put brown stains everywhere. I have cleaned the stain off. I have not found gasoline odor or visible leakage there-yet! Just got the car. So far I have changed the oil (Valvoline synthetic), air filter, bypassed the airbox thermostat (it was stuck in full-hot mode) and done the Italian tuneup. Today it's coolant change,spark plugs-might wait on that until I can get the three-prong ones from the dealer.
The car has 153K miles, BTW.
sredwine '94 940T at 236K

Dear srredwine,

May this find you well. If memory serves, fuel rail leaks sometimes are evident only by a gasoline smell.

A way to detect leakage (no, don't use a match!!!) is to wrap some new white paper towel around the front end cap. Secure the towel with tape.

Drive a mile or two, i.e., not enough for the engine to warm fully (engine heat will speed evaporation). Check the paper towel. If is is discolored - and/or if there's a faint gasoline odor - there may be a fuel leak. The fuel may have evaporated to the point that the towel feels dry. Even so, the fuel residue will discolor the towel.

If you find a leak, I'd not drive the car until I'd replaced the fuel rail.

Hope this helps.

Yours faithfully,

Spook

Thanks, spook-I tried your method, got no residue although I might have driven too far-but only thing on paper towel was flecks of black oil leak residue. I'll continue to monitor. Is there a source of photos or drawings that clearly identify the new design rail? This car might have already had its rail replaced.

thank you,
sredwine

Dear sredwine,

May this find you well. Paulii - a Master Tech - noted on another post, that he has repaired leadking 960 fuel rails, by peening the cap. This method involves using a hammer, to compress the metal. It takes a lot of skill - which Paulii has in super-abundance. I asked him to describe in detail, how he does this, e.g., tools used, etc.

As I'm not a 960 operator, I don't know if Volvo put a mark on the new model rail, to differentiate it from the factory-original. On the 1995 and later 960s, the fuel rail ("fuel pipe" is the Volvo term) is Part #9179348. On the 1994 models, it is Part #6842642. On the 1992 and 1993 models, it is Part #3507853.

I'd guess these will interchange, and that Part #9179348 is the upgraded version. I'll let one of the Board's 960 experts have the last word, though. One of them will have done this upgrade, and be able to answer authoritatively.

Hope this helps.

Yours faithfully,

Spook