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Discussion Starter #1
Hello,

I just completed rebuilding the engine of my 1964 Volvo 544. It runs great after the rubuild, but when I filled the gas tank I got a gas leak. It looks like the leak is coming from the fuel tank where the tank connects to the fuel line. I'm told this is the sending unit? The gasket seems to have worn down over years of being parked in a garage. Any insight or direction to resolving this issue would be very helpful.

Thanks,
PAK544
 

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Discussion Starter #2
Update

So it turns out I was wrong. The leak was coming from the return fuel line not from the sending unit. I put some gasket maker liquid seal on the washer as a temporary fix to stop the leak (I think it was welded originally). Still looking for ideas to put in a permanent fix.
 

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The 544 does not have a fuel return, only the fuel outlet to the fuel pump on a 5/16" line (#11). The vent appears to be on the filler neck. Compare your car with the pic from this website;
PV544
section 02c

 

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...so, if the fitting is broken there, you will have to have the tank fixed or replaced - depends on your budget and long term plans for the car.

If you elect to fix, the tank will have to come out, be professionally cleaned of old fuel and the fumes controlled so the repair can safely be made. This is not a job for unskilled tinkerers.

A new tank could cost close to the same as the repair. You would have the same labor to r&r but in the end, you have a new, rust free tank.
 

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Discussion Starter #5
BHart,

Thanks for the intuitive response. I was afraid the work might be extensive. The fitting is not quite "broken", but the washer that rests between the tank wall and the fitting is separating from the wall. I used a gasket maker seal to seal it back up as a temporary fix. It looks like it was either welded or soldered originally. Any recommendations of where I can get a new tank?
 

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Christer at VP Autoparts is in South Carolina. They deal in older Volvo parts. I got my new 1800 tank there.
 
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