My 2005 XC90 2.5t awd rebuild

ngarover · Post by **ngarover** » 26 Sep 2018, 18:32

I have an issue with a rusting fuel pump ring, or something else in the tank causing rust to flake and get into the fuel pump/filter. they have been replaced twice before dealer had truck and found issue. First garage replaced the fuel pump/filter and it got plugged again, twice. Anyways, I have a spare replacement tank already, and I helped take it out of a parts xc90 of same year model, except most of the work had been done before I got there. (drive shaft, muffler etc. already out. Does anyone have the manual to show the instructions of putting the new one back in?

I have not personally seen what the issue is yet as this all happened under my Ex wife. I'm buying the car back from her to fix so I'm going by what the dealer said. They had it over a month and did the full check of the car, but it was cost prohibitive for them to resolve.

Thanks

Post by **SuperHerman** » 26 Sep 2018, 19:05

See this thread: viewtopic.php?f=10&t=86297&start=10

PM the OP and ask if he still has the instructions and can send them to you, hopefully he still has them. I am out of town for the next 7-10 days, but he should have them.

Otherwise some one with VIDA may help. Just print to PDF and email.

ngarover · Post by **ngarover** » 27 Sep 2018, 15:55

Thanks

I looked over the thread and didn't see any actual instructions on removing or replacing the tank. Seems he was able to flush his system. I'll know more once truck is here and I can dig into it myself. I'll do pictures etc of the process as I go.

Post by **SuperHerman** » 27 Sep 2018, 19:44

I sent you a pm. If you have no luck pm me next week.

Taking actual photos and doing a write up is a great idea.

ngarover · Post by **ngarover** » 30 Sep 2018, 18:25

Ya, it was a pita getting the tank off the old one even after everything was removed. Dealer wants 2500 to do the job. It's a 2005 Volvo xc90 2.5 AWD with only 130K on it, Brand new tires, Bosch Quiet cast Rotors and brakes (I put them all on)

and I'm buying it back as is for 800 bucks, so it's a steal if I can get it back together. Less than what I originally paid for the tires. I hope to have it here in a couple weeks to start working on it.

It does have some other issues, like a broken rear wiper, bad rear door handle and mechanism and torn drivers side rear door seal, all the parts I was able to also get off the donor. Plus it has the new fuel pump (orielys) which has receipt so I could swap it out if I need to . I got the original one in the spare tank as well.

ngarover · Post by **ngarover** » 27 Oct 2018, 16:55

Started work in the 2005 Volvo. Its a real mess. Was able to drive it home 45 miles with 2 inches of water above the carpets. The Anti Skid unit underwater. Hope to grab the one out of thats parts truck. Anyways I was able to start drying it out, Got 90 % of the water out and did a repair to both sunroof drains as shown in the pictures. Both had shrunk from heat and where a whole 2 inches away from the rubber 90 angles. both had of course been dumper all rain right into the truck all summer. I got some plastic tube that the originals fit in and then used clear silicon to attach them and seal up where they pass into the drain of the a pillar. rained all week and no more water inside from it

Today I was able to remove all the seats, side panels etc in prep for pulling out the carpet and matting both can be saved with a good shampoo and drying I think and a good soak in some anti mold solution there was mold growing in the rear carpets.

Also replaced the rear wiper motor and arm, and the rear door hatch handle with parts for the donor both like new and working great now. Getting the 3rd row out was a little bit of a job

Learning as I go here, working on getting the center column out now.

ngarover · Post by **ngarover** » 27 Oct 2018, 18:19

Carpet all out took all day but was able to use wet dry to suck remaining water. The carpets where bone dry but I got 4.5 gallons out of it not including what's trapped in the foam padding. everything sitting outside to dry then the cleaning/repair begins. not a bad days work.

Post by **SuperHerman** » 28 Oct 2018, 14:50

I just went through this with my BMW, but only the back carpet. Pulled it out, did a serious rinse job with a garden hose and scrubbed down with carpet cleaner. Once I was happy it was as clean as it would get I wiped the foam side with some diluted bleach and let it dry in direct sunlight for a week. Put it all back together and zero smell. Car carpet is pretty robust and takes this type of cleaning well. I also sprayed and wiped the hard floors with the bleach solution. Should kill all the mold - just take care not to bleach the carpet.

ngarover · Post by **ngarover** » 28 Oct 2018, 18:04

More today, Waiting on tool to remove fuel pump ring. Took off the fuel filter and cut it open only to find it clean. I was told that this tank was full of rust This fuel filter has 300 miles on it and not a speck in it. Still going to pull out the fuel pump and endoscope tank. Maybe lager crap in there..

Took all carpet and parts out and gave everything a good power washing and shampoo. aside from a few small stains, it looks almost new and the smells all gone. Only a the front parts dried enough to put back in but the front is all but back together sans seats.

Check a wire connector the was below water line and sure enough it was burnt inside. from outside it looked fine have soldered the wires and water proofed.

Plan it to troubleshoot this fuel issue. Replace all vacuum lines. Replace Timing belt and tensioner. New spark plugs/wires. Compression test on the engine itself. Replace exhaust and replace suspension parts needing it. It has 175K on it. I believe that timing belt is original. Scary to me. With fuel issues I'm fully expecting Cats to be shot. maybe get lucky who knows. It's due for o2 sensors as well.

Ordered the spanner tool for the fuel pump, a new fuel filter, and the Volvo diagnostic OB2 computer that has gotten good reviews and is able to clear the Air bag fault...yes I turned the key with the seats out...sigh..

Also have requested a quote to Fibernew to re-dye the steering wheel and the front seats and to fix a seam on the drivers seat

ngarover · Post by **ngarover** » 03 Nov 2018, 11:43

OK, so have wrong fuel pump in it. Need to order the correct on to continue https://www.amazon.com/GENUINE-VOLVO-31 ... B00L2N3RA4