2005 xc90 fuel sender leak

Post by **ZionXIX** » 22 Mar 2024, 22:17

As part of my mini restoration I've been chasing a fuel tank leak. Ever since I replaced the fuel I have gas pooling on top of the fuel sender. Originally I did not change o-ring but since chasing the leak i have. I put a volvo brand o-ring, cleaning the sealing surface very well and greased the o-ring. I made sure the sending unit was seated all the way down before thread the lock ring. Arrow is pointed back and I've tightened the ring, a lot. After doing this job twice I went to fill up and noticed gas again but this time it coming from the top on the wired asymmetric raised plastic on top of the sending unit. Do I need to replace the sending unit at this point?

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Post by **ZionXIX** » 01 Apr 2024, 11:13

Replaced the fuel sender today with a Bosch unit from FCP. Filled up 2 hours ago and so far no fuel smell and no leaks. I'm gonna give it a little time and then these seats are going back in!

Post by **shiloh51933** » 09 Apr 2024, 07:05

ZionXIX wrote: ↑01 Apr 2024, 11:13 Replaced the fuel sender today with a Bosch unit from FCP. Filled up 2 hours ago and so far no fuel smell and no leaks. I'm gonna give it a little time and then these seats are going back in!

I had the same issue on our 2004 vXC90 T6 and i ended replacing the sending unit and fuel pump assembly at the same time with the factory assemblies(which is Bosch). I purchased the assemblies from FCP too, actually I purchase 90% of our Volvo parts/maintenance items from FCP.