Fuel Pump Recall announced

[enotslim]

... you should get a feel of whether it’ll be ok to drive 5 miles...

Leaks immediately when pump activates as shown in the video here. No spray though. I'll watch with engine running. Maybe it slows when fuel is consumed (if pressure drops).

[Krons]

I’d definitely run it to the dealership like that rather than tow it.

For dramatic effect you could cover it with a shop rag and throw it fuel soaked on the service writers desk. Wait…don’t do that…

[enotslim]

- Drove to dealer who did steering wheel air bag recall. Good color match (black) but not the same surface "reflection". It's fine.
- Unlike for other owners Volvo Customer Care would not cover fuel pump recall because we are beyond the extended warranty period offered outside the recall areas. Understandable, but delayed return 2 weeks (they could have denied coverage up front) so it's now too cold to replace myself or try temp epoxy repair in my driveway. May try epoxy in my parking lot at work.

[Krons]

- Drove to dealer who did steering wheel air bag recall. Good color match (black) but not the same surface "reflection". It's fine.
- Unlike for other owners Volvo Customer Care would not cover fuel pump recall because we are beyond the extended warranty period offered outside the recall areas. Understandable, but delayed return 2 weeks (they could have denied coverage up front) so it's now too cold to replace myself or try temp epoxy repair in my driveway. May try epoxy in my parking lot at work.

May be surprised how well the epoxy holds up. Prep it well and get a petroleum resistant variety and you may be good for a while.

[enotslim]

Would plastic welding be a death wish? Seems most likely to actually repair, not just plug, the leak and be a longer term fix (absent a conflagration).

[Krons]

Would plastic welding be a death wish? Seems most likely to actually repair, not just plug, the leak and be a longer term fix (absent a conflagration).

Heating elements and fuel are always a bad idea. Scuffing the plastic with 40-grit to add some bite and a fuel compatible epoxy will do the job.

[enotslim]

I did the J-B Weld fix of the one quadrant of the cap that was obviously leaking. So far so good but I’ve only driven far enough to put 2 gallons of fuel in the tank ~ less than 2 miles total. After getting 2 different opinions from the J-B Weld help line I used Water Weld 8277 because it is advertised for many but not all plastics, is resistant to oil, gas, diesel, “most chemicals” and more and, importantly, sets up in 20 minutes and cures in 4 hours. I had one 12 hour interval at 60 degree exterior temperature and didn’t want to risk using something that advertises 24-48 hours to cure. Fingers crossed that this holds at least until Spring when the pump really should be replaced.

[dono]

On mine it was easy, they just had to look at my epoxied fuel pump top (I didn’t want fuel blowing up my car) and smell the gas from the seat bottom. All they really need is a “yup, top of fuel pump is cracked” so they can work a ticket with Volvo USA. I don’t know why dealers sometimes make it more difficult than needed.

Dealer won't look at the fuel pump with epoxy (to stop the leak so I can drive it in). That means towing, both ways if Volvo US rejects coverage under the recall (and I replace the pump in my driveway or just try epoxy at that point). Any way to reversibly stop/slow the leak enough to drive 5 miles to the dealer? Inflatable balloon stopper? If not I guess I tow and hope. They will do the air bag recall at the same visit.

Enot,

Hope you got this fixed by now. If you are worried about fire just pull the rear seat, open the windows, grab an extinguisher and drive to the dealer - you are not going to burst into flames on a half hour drive with the seat off and windows open. I drove around for a week or two before it got bad enough to figure out.

I think the main reason they will cover you is liability - if your car does burn up Id say you have an excellent case to sue them for refusing to repair a known latent defect because of your geographical location.

[enotslim]

Enot,

Hope you got this fixed by now. If you are worried about fire just pull the rear seat, open the windows, grab an extinguisher and drive to the dealer - you are not going to burst into flames on a half hour drive with the seat off and windows open. I drove around for a week or two before it got bad enough to figure out.

I think the main reason they will cover you is liability - if your car does burn up Id say you have an excellent case to sue them for refusing to repair a known latent defect because of your geographical location.

The dealer/Volvo USA (or whatever) did not cover the fuel pump. The car was in for the air bag recall so it wasn't the inconvenience it would otherwise have been.

The JB Weld is still holding almost four months later so I guess it is more than a transient solution. I've still been very cautious. Last weekend was the first time I put more than $10 fuel in the tank, starting from nearly empty, just in case I need to remove the pump. Don't want to spill into the interior or to figure out how to remove fuel past the siphon preventer.