1997 Volvo 960 Fuel System, Gasoline Fuel Injection System Problems, Complaints and Defects, Recalls and Failures

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1997 Volvo 960 Fuel System, Gasoline Fuel Injection System Problems, Complaints and Defects

 Issue ID903999
 Internal NHTSA #10445680
 ManufacurerVOLVO CARS OF N.A. LLC.
 Model Year1997
 File date28/01/12
Product type codeVEHICLE
 Description of the problemSmelled fuel in engine compartment,opened hood and found a leaking fuel injection supply rail. Leak stems from the end cap used on fuel rail towards the front of the engine near the thermostat housing and proceeds to drip vigorously down towards the intake manifold before evaporating and dripping down onto lower part of the engine and finally the ground. I have found several comments in the internet forums related to this possible defect in the manufacturing of this part stating that the leak is located in the end cap of the fuel rail, and volvo has a re engineered fuel rail that eliminates the leaking end cap and is currently offering this re engineered part as a replacement at a normal retail labor and parts rate. Since modern vehicles are designed to operate beyond the traditional mileage of 100k , the general public is not expecting to have such a safety hazard present itself by a failing fuel rail end cap, in addition the volvo owners manual does not recommend any maintenance of the fuel rail at any specific mileage thus misleading the public by the omission that such a part should be replaced before failure occurs. In addition volvo has re engineered the part and is currently profiting from the safety hazard that this fuel rail has created. Volvo has in the past and currently advertised itself as reliable and safe, thus creating a certain expectation of high safety standards and high safety ratings, and volvo should (in keeping with it's public image) at it's own expense remedy this problem by conducting a vehicle safety improvement campaign such as nissan motor co. Has done in the past(nhtsa campaign id number: 95i006000) to prevent any possible injuries that may result from leaking fuel systems that have not been altered or modified by current or previous owners and reimburse those that have already replaced the leaking fuel rails at their own expense.
 Vehicle Mileage at Failure154000
Number of Occurences1
Source of the issueNHTSA WEB SITE
 City and StateFORT WORTH, TX
 Was vehicle invloved in a crash?N
 Was vehicle involved in a fire?N
 Was incedent reported to police?N
 Was medical attention required?
 Was part original equipment?
No. of injured persons
No. of fatalities
 Date of purchase23/06/21
Was original owner?N
Anti-lock brakesN
Cruise controlN
Number of cylinders6
Drive train type
Transmission type
 Vehicle speed0
 DoT tire identifier
 Tire size
 Location of tire code
 Type of tire failure code
 Was defective tire repaired?
 Date of manufacture
Type of child seat code
Type of restraint
 Dealer's name
 Dealer's telephone number
 Dealer's city
 Dealer's state code
 Dealer's ZIP code
  • What is Recall?

    A recall is when a product is removed from the market or a correction is made to the product because it is either defective or potentially harmful.
  • What is Failure?

    Failure is the state or condition of not meeting a desirable or intended objective, and may be viewed as the opposite of success. Product failure ranges from failure to sell the product to fracture of the product, in the worst cases leading to personal injury, the province of forensic engineering.
  • What is Defect?

    Non-conformance of a car component with the specified requirements, or non-fulfillment of user expectations, including the safety aspects.
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