Four problems related to tank assembly have been reported for the 1999 Volvo S80. The most recently reported issues are listed below.
The contact owns a 1999 Volvo S80. While driving approximately 60 mph the vehicle suddenly stalled. A road side assistance technician inspected the vehicle and stated the fuel tank was empty. The contact stated the fuel gauge did not read empty at the time the vehicle stalled. The vehicle was taken to the dealer for diagnostic testing. The VIN was not available. The approximate failure mileage was 70,000.
While driving at any speed vehicle stalled, and then won't start again. Vehicle was towed to the dealership. Floor manager indicated, a pipe on the fuel rail broke and needed to be replaced at consumer's expense of $1200. Consumer indicated the fuel tank/fuel pump, and fuel rail was just one unit.
While driving 55-60 mph, brakes were pulsating, after applying brakes again noticed brakes were fading. Consumer pulled over and noticed rotors were red hot. Dealer replaced front rotors and pads. The gas tank had a defect that would cause a vacuum leak. The front suspension makes a cracking noise when turning due to ball joint failure. The gear shifter switch makes loud clicking noise. The rear passenger door handle could not be opened from outside. Automatic transmission had slippage and shudder while up shifting, creating a vehicle loss of control. Passenger side rear seat backrest cushion makes noise due to loose clips. The front passenger window developed a wind noise due to defective window seals. Due to design fault, the upper torque mount bushing cracked. The driver side front headlight lens broke. The consumer is asking for a full refund of the actual price paid for the vehicle or for it to be replaced with a new equally equipped vehicle.
While attempting to fill the fuel tank (3/4 empty, 112 degrees f), the tank would not accept fuel. I removed the nozzle to see if the filler was obstructed, and a geyser of pressurized gasoline was ejected from the filler neck lasting about five seconds, and drenching my clothing and the ground in a puddle of gasoline. Fortunately there were no ignition sources present .