P2 Fuel Sender Leak

[ZionXIX]

Cross post from the XC90 forum. It's uh pretty quite over there. Anyway here's the situation.

"As part of my mini restoration I've been chasing a fuel tank leak. Ever since I replaced the fuel pump 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, cleaned 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?"

[scot850]

Looking at your picture above, if you look at the middle bottom of the picture on the raised portion, there is a crack in the casing. I would suggest this may well be the cause of your leak.

Neil.