Car troubles/mechanic troubles. Who do I trust??

summervolvo · Post by **summervolvo** » 15 Sep 2009, 20:21

My 2003 S60 broke down and I went to a Bosch certified mechanic who said I needed new fuel pump and new fuel pump control module. I paid for the repairs and 1 month later my car wouldn't start and smelled of gas. I then took it to a Volvo dealer/ service dept and they said my car had no fuel pressure, they removed the fuel pump cover and found connectors slightly damaged and fuel line not connected, they attempted to reconnect the fuel line but was unable to due to fuel line lock being damaged (they believe by the use of wrong tools and/or inferior workmanship). They said I now need a new fuel tank. The first mechanic says he didn't cause this problem and he wants to inspect my car, I don't want him to touch the car. Anyone know anything about the fuel system? Does this make sense? Who do I trust? Should the first mechanic be responsible for the cost of new repairs? any help is greatly appreciated!

Post by **JDS60R** » 16 Sep 2009, 02:04

I will ask some others on chime in on this as I am away from my reference manuals but something sounds wrong here and we could use a few pictures.

Usually the fuel line is connected to the pump assembly so needing a ful tank would not make sense. I know that tere may be split tanks in the S60 so it is possible that a line that connects the tanks has now broken.

Can you send us some pictures of the broken parts so we can see what you are refering to.

In order to know who to trust we will need to see the removal instructions for the fuel pump and see if your broken part would have been touched by the first mechanic.I am sure someone with Vadis will let us know shortly.

Please let us know what dealership you are dealing with and perhaps someone here can speak to their abilities, honesty, etc

Sorry I can't be of more help but I am out of town and away from my vadis .

summervolvo · Post by **summervolvo** » 16 Sep 2009, 09:19

Thanks for your response...I'm afraid I don't have any pics of the messed up parts. The volvo dealer said that the fuel line lock (is this a part of the fuel tank?) was stripped- probably by the use of the wrong tools. Because this part was stripped they couldn't re-connect the fuel pump to the fuel tank (I think I'm saying that right) and thats why they say I need a new fuel tank. Volvo did a quick fix and rigged it together with zip ties but they say they cannot gurantee this job and to fix correctly I will need a new fuel tank. Picture diagrams would be a great help so I could understand this better. I suppose I could always ask Volvo to write an affidavit stating there belief on the cause of the damage...

Post by **JDS60R** » 18 Sep 2009, 17:01

Ok, I got a copy of VADIS so I can see the issue now. (See attached diagram).
The tank is not split in two.
The main pressure lines are on the fuel pump insert .
There is one line (possible vent or return line) that is between aprts 24 and 25.

I would think that a splice-in repair coupling would be available. I see no reason why you would need a new tank.

Call a different dealer and ask if they can get a splice in connector to fix that issue. Ford (owns Volvo) makes a repair kit for about every electrical connection and fuel line they make.

If you must get a tank - get a used one. These are not made of metal .

Post by **JDS60R** » 18 Sep 2009, 22:08

It looks like you do not need to take out the gas tank to change the fuel pump. If these are the connections that are damaged then you would only need the assembly the fuel pump is in and the tank.