Unusual EVAP leak. Fuel pump housing cracked

Andrew Vanis · Post by **Andrew Vanis** » 13 Jul 2024, 14:05

Chasing evap leaks the system actually finally held pressure but I ly up to 3psi. It was hissing from the fuel pump.

The soap bubbles were coming from the housing. Removal revealed a hairline crack.

Fix is a hot soldering iron to (cross fingers) plastic weld the crack.

Backup fix is is overlay of JB Weld. I melted in some holes on the sides of that section to hopefully retain the JB if it separates from plastic.

Since the only other option is a new pump I'm giving this a try.

Post by **scot850** » 13 Jul 2024, 23:08

Is the JB weld you used rated for use with fuel? AS the saying goes, it will either work or not. You have spent some time on this and hopefully you get a successful result.

Neil.

Andrew Vanis · Post by **Andrew Vanis** » 14 Jul 2024, 07:35

Re JB+gas... IDK. It's what I had in hand and couldn't get another decent price pump housing in the time I had so rolled the dice.

It works and holds 5psi no issue. Now it's just for how long.

Post by **scot850** » 14 Jul 2024, 09:06

That crack is close to the top, so perhaps don't fill the tank all the way? Maybe only fill to 2/3 or 3/4 to try to minimize the JB Weld sitting in gas for prolonged periods.

Neil.

Post by **Krons** » 14 Jul 2024, 13:25

There was a recall in the southern US with fuel pumps cracking, I called Volvo Customer Care to open a case and they covered it for me. 2002 S60 with I think 188k miles at the time. I think a fuel rated epoxy would for sure hold temporarily. Ultimate fix is a new fuel pump.

Andrew Vanis · Post by **Andrew Vanis** » 15 Jul 2024, 08:46

Krons wrote: ↑14 Jul 2024, 13:25 There was a recall in the southern US with fuel pumps cracking, I called Volvo Customer Care to open a case and they covered it for me. 2002 S60 with I think 188k miles at the time. I think a fuel rated epoxy would for sure hold temporarily. Ultimate fix is a new fuel pump.

That is good to know! Is there a recall check I can do online, or is calling the dealer the best way to check?

Post by **scot850** » 15 Jul 2024, 13:35

The recall may have expired, but worth calling and asking a dealer to look into it and with your Vin# if it was done already.

Wish you luck on this one!

Neil.

Post by **Krons** » 15 Jul 2024, 18:00

Andrew Vanis wrote: ↑15 Jul 2024, 08:46
Krons wrote: ↑14 Jul 2024, 13:25 There was a recall in the southern US with fuel pumps cracking, I called Volvo Customer Care to open a case and they covered it for me. 2002 S60 with I think 188k miles at the time. I think a fuel rated epoxy would for sure hold temporarily. Ultimate fix is a new fuel pump.
That is good to know! Is there a recall check I can do online, or is calling the dealer the best way to check?

Looks like you’d be out of the suspect range.
https://static.nhtsa.gov/odi/rcl/2009/R ... 3-8017.pdf

Andrew Vanis · Post by **Andrew Vanis** » 15 Jul 2024, 18:10

Thanks for that. Shows the earliest models covered are 2001

What steps or search terms did you use to find that?

Post by **abscate** » 15 Jul 2024, 23:35

You go to the NTSA site and punch in your VIN.