Fuel Issues even after new pump

nutcase · Post by **nutcase** » 24 Jan 2021, 10:09

I have a 2008 S60 Turbo and it was getting very difficult to start. I read that the two most common causes were bad seals on the fuel injectors and a bad fuel pump.

I replaced the seals on the injectors and I believe the car ran better - but didn't solve the hard to start issue.

I replaced the fuel pump with a new Bosch pump. I made the mistake of having a full tank, so some gasoline came up into the cabin when I opened the lower access hole. So I had a fuel smell in the car. I put in a big blower and tried to dry everything out and there was still a lingering odor. It is now a month later and the car has issues (including the gasoline smell - even outside the car).

In addition to smelling gasoline fumes outside the car, it still has a small starting issue. Nothing like before, but it takes two-three tries to start it. Then I noticed that when I got to 1/8th of the tank and I went on a downhill road with a sharp right turn at the bottom the engine would die. Happened twice in the same spot. Then today with 1/3rd of the tank the car started acting like it was going to stall on the interstate. Finally the check engine light came on and when I pulled into a gas station I checked for error codes. I had one that the pressure in the fuel rail system was too low and another one about the fuel pressure regulator (Don't remember the exact codes). I filled up the tank and came back home - no issues with a full tank.

I suppose I could always drive with at least 1/2 tank of gas in the mean time.

So, Do I pull out the new fuel pump and reinsert it or simply replace it. Do I have another problem? Why the continuous faint odor of gasoline?

Post by **abscate** » 24 Jan 2021, 10:14

Is your S60 a FWD or Awd model? It sounds like a saddle Tank issue , Awd only, though.

nutcase · Post by **nutcase** » 24 Jan 2021, 10:23

Front wheel drive.

Post by **erikv11** » 24 Jan 2021, 10:32

The fuel pressure sensor is a very common failure item on P2 cars. If it has never been replaced, it may be an issue here. Might troubleshoot with a junkyard one. Bosch makes the factory one, about 50 bucks.

Post by **oragex** » 24 Jan 2021, 11:21

For the gasoline smell, lift the rear seats and remove the rear floor mat, and spray everything with Simple Green - actually the mats have absorbed gasoline so worth completely removing them. As above, I suggest google about FPS (see Fcpeuro.com and undo with cold engine and release the pressure at the rail valve) and PEM (buy only used off ebay) however, I personally don't see how these would be related to car taking a turn and stall but worth replacing the FPS as maintenance. Smear the FPS seal with vaseline before placing back (see Youtube). When placing back the new pump inside the tank, one must be careful not to kink the hose under the pump. I'm not saying this is your problem, but it's good to make sure. May also want to check the cable connections at the battery, starter, fuse panels

nutcase · Post by **nutcase** » 09 Feb 2021, 09:13

So I pulled out the new Bosch fuel pump and cleaned the groove where the seal goes, inserted a new seal and reinstalled. I then went to the fuel rail to see if the problem with the smells could be there. Well, I broke the two plastic pieces that connect the fuel line to the fuel rail. Then I had problems getting it connected again. Gas would squirt out as soon as the fuel pump kicks on. I had to use a pry bar to force the fuel line to go far enough into the fuel rail to go into the seal. Then tighten the plastic connectors.

So that brings me to where I am now. I still have a faint gas fume smell in the cabin. When I smell around in the back seat I don't smell it as bad as in the front seat.

My next step in trying to solve this problem is to replace the line from the pump to the fuel filter and replace the fuel filter.

Questions
Where does the other line go out of the fuel pump? How hard is it to replace it?
How hard is it to replace the line from the fuel filter to the fuel rail (Don't want to - but I'm running out of options)?
Other suggestions?

jgadbois · Post by **jgadbois** » 09 Feb 2021, 16:09

Sounds like your initial problem was caused by the fuel pickup becoming disconnected from the spring loaded part of the fuel level sensor assembly in the access hole opposite the one with pump. The spring loaded part forces the pickup to the bottom of the fuel tank. If it came loose the pickup will move around in the tank during turns and braking. Did you replace both o-rings? If they are reused or not seated properly they can cause a leak. This happened to me during my recent pump replacement in a 2006 XC70.

nutcase · Post by **nutcase** » 06 Mar 2021, 10:26

I have solved both of my problems - gasoline smell in the cabin and losing pressure in the fuel rail.
Gasoline smell in the cabin - I had installed a new fuel pump. I went back and tightened the hold down ring as hard as I could and the problem went away.
Fuel Rail losing pressure - I purchased a used fuel rail off ebay. It had the push button fuel line locking mechanism. I put it and 4 of the fuel injectors on the original fuel rail. The seals on the ebay fuel injectors seemed to fit tighter in the original fuel rail. It took a lot of effort to get the fuel rail far enough into the locking mechanism but once it did and I installed everything - I haven't lost pressure.

darylrobert · Post by **darylrobert** » 10 Mar 2021, 03:36

probably too late but i hope you use some white lithium grease on those o rings? they should just slide in without force