1997 Volvo 960

SMELLED 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. *TR

CHECK ENGINE LIGHT CAME ON THEN LOW COOLANT LIGHT. SUDDENLY LOST POWER DUE TO ENGINE FAILURE. IT SEIZED UP DUE TO OVERHEATING. TEMPERATURE GAUGE NEVER REGISTERED HOT. RADIATOR NECK BROKE OFF AT NECK CAUSING LOST OF COOLANT. ENGINE RUINED. DEALER WILL NOT REPLACE CLAIMING THERMOSTAT STUCK EVEN THOUGH THEY COULDN'T PROVE THIS. *JB

VOLVO DEALER, UNDER WARRANTY REPLACED ALL 4 DISC BRAKE ROTORS & PADS DUE TO WARPING OF ROTORS & RESULTING VIBRATION WHEN SLOWING DOWN FROM 65 MPH TO 50 MPH ON HIGHWAY. THIS WORK WAS DONE ON 11/14/00 AT 39,024 MILES ON THE CAR. IT IS NOW 6/29/01 AND THE CAR ONLY HAS 43,500 MILES ON IT, IE. ONLY 4,500 ADDITIONAL MILES ON IT. THIS HAS NOT BEEN A PROBLEM ON OUR OTHER CARS, SO IT SHOULD NOT BE ATTRIBUTED TO DRIVER ERROR OR OTHER DRIVER-RELATED CHARACTERISTICS. IN FACT, WE GET VERY GOOD BRAKE WEAR AND DURABILITY ON OUR OTHERS CARS WITH THE SAME DRIVERS. IN THE APRIL, 2001 ISSUE OF CONSUMER REPORTS MAGAZINE, THIS CAR FOR THE 1997 MODEL YEAR RECEIVED THE WORST AVAILABLE RATING FOR THE BRAKES RELATIVE TO FREQUENCY OF REPAIRS FROM OWNER SURVEYS CONDUCTED BY THE MAGAZINE. I STRONGLY BELIEVE THAT THIS VIBRATION DUE TO DISC ROTOR WARPAGE CAN LEAD TO FURTHER DAMAGE IN THE BRAKING SYSTEM AND ULTIMATELY CAUSE A SAFETY RELATED FAILURE. I WOULD LIKE TO BE CONTACTED TO DISCUSS THIS FURTHER AND TO INQUIRE IF YOU HAVE FOUND THIS TO BE A PROBLEM ON OTHER VOLVO 960'S OF SIMILAR VINTAGE AS CONSUMER REPORTS HAS FOUND AND ALSO AS I HAVE PERSONALLY FOUND TO BE THE CASE. *AK

WITH NO INDICATION OF OVERHEATING THE ENGINE OVERHEATED AND WAS DESTROYED. THE ONLY IDIOT LIGHT TO COME ON WAS THE CHECK ENGINE LIGHT AND THAT WAS AFTER BLACK SMOKE WAS COMING FROM THE ENGINE. THE TEMPERATURE GAUGE NEVER REGISTERED OUTSIDE OF THE NORMAL RANGE AND NO OTHER WARNING LIGHTS WERE ACTIVATED. THE ENGINE NEEDS TO BE REPLACED ACCORDING TO VOLVO BUT THIS IS NOT COVERED UNDER MY EXTENDED WARRANTY BECAUSE THEY STATE IT DOES NOT MATTER THAT THE GAUGES MALFUNCTIONED AND THEY CAN NOT BE TESTED ANYWAY BECAUSE THE CAR CAN NOT BE STARTED.*AK