2001 V70 2.4T Long crank after sitting, fuel odor, underside of fuel tank damp Topic is solved

[prwood]

Can anyone point me to a good video or article on removing the back rests in a P2 wagon? What I’m finding is mostly for P80 models or for P2 sedans.

Sorry I assumed they were the same.

Here's one.

Yup, I saw that one... it’s just for the seat cushions, not the seat backs.

[dlundblad]

Can anyone point me to a good video or article on removing the back rests in a P2 wagon? What I’m finding is mostly for P80 models or for P2 sedans.

Sorry I assumed they were the same.

Here's one.

Yup, I saw that one... it’s just for the seat cushions, not the seat backs.

Are you sure that's different than S60's? Removing the "wings" should expose some bolts if I remember correctly.

The now fiance and I did this in 10*F weather in the dark 2 years ago. Wasn't exactly shall we say a pleasant experience.

[prwood]

I found some good videos when i searched for “replacing Volvo fuel pump” instead of “removing backrest”.

It turned out not to be too bad to remove the backrest. Disconnected battery, removed side cushion, disconnected SRS cable, removed three bolts. Pulled seat hard sideways so that the post slid out of the other seat, and moved the backrest into the cargo area.

The fuel pump looks like an animal has been using it as a storage place for nuts. I can’t see any cracks, but it looks like the leak was coming from the cross/circle section. From what I’ve read, the cracks are mostly invisible and the solution as someone mentioned earlier is to just slather the whole area with epoxy.

I cleaned everything with brake cleaner and dried it off the best I could. I’m going to give it overnight to dry out and then try the epoxy in the morning. Not sure how I’m going to fit sandpaper in all the deeper crevices on top to scuff it up but I can probably find a smaller tool to use.


Access panel

Access Panel

Before cleaning. Nut storage for animals. Fuel pooled in circle/cross section.

Before cleaning

After cleaning

After cleaning

[abscate]

Thanks for nice clear pictures.

Isn't there a gasket under the large nut know to leak? There have to be o rings in those fittings too. Maybe reconnect SRS and key on to check for leaks carefully?

[EngineeringBloke]

I see a crack in your after-cleaning photo. It is at the 4 o'clock position near the center on the half cylinder tube under the white cross on what looks like a one inch white nut.

There may be a crack in the big white disk from that nut (again at the 4 o'clock position, then going off to the right). But that may just be part of the molding.

Running the pump should show where the leaking is coming from, as abscate notes (especially if it is more than one location). Good idea to avoid the air bag light, too.

I would not think anything big enough to store nuts could ever get under the cover plate. I suspect Swedish Volvo assemblers hiding their snacks . If there is a small gap at the edge of the plate, perhaps the nuts or seeds just blew in there?

[prwood]

This morning, I reconnected the SRS connector, fuel line quick connects to the pump, and battery negative lead. Then I set up my phone on a tripod to film so I could easily identify where the leak was coming from. Here is what I captured, from when I turned the key to "II" to when enough fuel had pooled up so that it spilled over. Clicking on the image below will take you to a video player on my photo gallery.



You don't see anything right away when the fuel pump activates, but at about 30 seconds (right after I cough) you can see the first signs that fuel is coming up, because there is a speck of dirt that starts to float. As you can see, the leakage originates in the bottom left quadrant of the "turret" on the top right of the pump. (P.S. I don't know the proper name for that extrusion...). When I start the engine, it starts to rise a bit faster. The fuel slowly rises until it starts spilling into the quadrant next to it and over the edge onto the top of the pump below.

Based on this, I cleaned everything up again, scored the inside with a screwdriver, and applied JB Weld (original formula) to the section that was leaking, as well as the section next to it for good measure. There are some very skinny channels around the edges of the "tower" which is where the leak started, and I did my best to try and stuff the JB Weld down there. When I was done I couldn't see any more white plastic.

I'm going to allow the full 24 hour cure time before I start it up again to see if the patch holds.

[prwood]

I see a crack in your after-cleaning photo. It is at the 4 o'clock position near the center on the half cylinder tube under the white cross on what looks like a one inch white nut.

There may be a crack in the big white disk from that nut (again at the 4 o'clock position, then going off to the right). But that may just be part of the molding.

Here's a better closeup of the pump. I think both of those things may be part of the molding:

PumpCloseup.png (1.53 MiB) Viewed 1688 times

I would not think anything big enough to store nuts could ever get under the cover plate. I suspect Swedish Volvo assemblers hiding their snacks . If there is a small gap at the edge of the plate, perhaps the nuts or seeds just blew in there?

I don't think anything is getting under the cover plate. My suspicion is that whatever animal it was, was taking the reverse path of the fuel when it leaks underneath the car: coming from under the car, and climbing up over the top of the fuel tank so that they end up squeezing between the top of the tank and the underside of the chassis. Once they reached the circular space between the top of the fuel pump and the interior cover plate, it would be relatively roomy so it's probably a good place to store things. I'm thinking there's probably a passage that a mouse could fit through to get up in there.

[prwood]

And that's a negative on the JB Weld stopping the leak, at least in my case. :-\ Maybe someone else could have done a better job, but at this point, since I've already got half of the backseat taken apart, I'm just going to replace the pump.

I'm planning to order the Bosch fuel pump from FCP:

https://www.fcpeuro.com/products/volvo- ... 0-30761743

As well as o-rings for both the fuel pump and fuel level sender:

https://www.fcpeuro.com/products/volvo- ... nk-9183708

There's a special ($50) tool to remove the locking rings, but I've also seen some homemade tools, and one video where someone used a hammer and chisel to tap it loose. It seems to be pretty sturdy plastic so I don't think I'd have a problem doing that.

Also wondering if there are any other parts I should consider replacing while I have this all torn apart, or any other maintenance to do (besides vacuuming out a ton of junk, including never-before-seen pet hair from the previous owner).

On another note, when I was taking out the left side backseat, I got a sightline through the hatch for the fuel pump straight out to the right rear wheel. There's definitely enough space for a small red squirrel to get through there...

[prwood]

Photo of the backseat / fuel tank area disassembled for reference.

The cover on the fuel sender looked like it had a really grimy old piece of tape across it, but it was so brittle it got sucked up when I was vacuuming.

[abscate]

Peter

Watch out for the routing of the pipes it he tank. It is easy to kink something and then you get a horrible intermittent fuel delivery problem like shockwave did on th e XC90 forum