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Fuel leaking from tank 2004 XC90

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo XC90s. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
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shiloh51933
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Fuel leaking from tank 2004 XC90

Post by shiloh51933 » Thu Jan 31, 2019 6:26 am

2004 XC90 T6 , leaking from passenger side right by front of tank, looks like its rolling from top or side of tank. What's on that side, sending unit?


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Re: Fuel leaking from tank 2004 XC90

Post by MagicMike » Thu Jan 31, 2019 7:09 pm

Ours was leaking from split hose that joins the filler tube and the tank. Cheap part, fiddly to replace but very doable.



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Re: Fuel leaking from tank 2004 XC90

Post by shiloh51933 » Sun Feb 03, 2019 12:38 pm

I found fuel pooled up on top of sending unit.
So I ordered new seal, lock ring and sending unit.
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SuperHerman
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Re: Fuel leaking from tank 2004 XC90

Post by SuperHerman » Sun Feb 03, 2019 12:57 pm

Good find. How bad does it smell in the car? Generally on Volvos of this era the fuel pump is the culprit.

The plastic on top gets brittle and starts to crack with age and time. It would make sense the sending unit side would do the same thing.

Some people fix the problem by "pooling" a thin layer of epoxy (like JB Weld) over the entire top to seal the leak. This is done after the area is cleaned up well and slightly roughened.

If you have to replace any hose clamps make sure you use the oetiker type if that was what was originally installed. If not many end up with fuel pressure issues shortly after the repair. Post more pictures if you could.



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shiloh51933
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Re: Fuel leaking from tank 2004 XC90

Post by shiloh51933 » Sun Feb 03, 2019 6:26 pm

SuperHerman wrote:
Sun Feb 03, 2019 12:57 pm
Good find. How bad does it smell in the car? Generally on Volvos of this era the fuel pump is the culprit.

The plastic on top gets brittle and starts to crack with age and time. It would make sense the sending unit side would do the same thing.

Some people fix the problem by "pooling" a thin layer of epoxy (like JB Weld) over the entire top to seal the leak. This is done after the area is cleaned up well and slightly roughened.
Btw, we couldn't smell inside the car unless windows were opened and it only leaked when it was filled up.
If you have to replace any hose clamps make sure you use the oetiker type if that was what was originally installed. If not many end up with fuel pressure issues shortly after the repair. Post more pictures if you could.
Thank you for your reply. There's no fuel hoses on this side , the sending unit side. The fuel pump was replaced at Ramsey Volvo around 110k and I believe the sending was also replaced at same time but I have to verify the sending unit replacement by goi g through my paperwork. The mounting design for the sending unit was poorly chosen, I'm guessing they designed it this way due to clearance issues. If you don't line up the top of the fuel sending unit perfectly and then seal/close lock ring perfectly I could see how it could leak.


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Re: Fuel leaking from tank 2004 XC90

Post by SuperHerman » Sun Feb 03, 2019 8:50 pm

That sheds some light on matters. From the factory, I have never heard of either side leaking while the car is young. After years of use the plastic top will fail and leak.

After replacement I have heard many stories of people messing up the o-ring seal - which may be what you have. If that is the case, you might be able to just replace that part and make sure it is seated properly. If it was serviced, which by its color it does look like it was, then Ramsey Volvo should fix it for free and pay you. They left you a potential bomb.



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shiloh51933
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Re: Fuel leaking from tank 2004 XC90

Post by shiloh51933 » Mon Feb 04, 2019 12:47 am

SuperHerman wrote:
Sun Feb 03, 2019 8:50 pm
That sheds some light on matters. From the factory, I have never heard of either side leaking while the car is young. After years of use the plastic top will fail and leak.

After replacement I have heard many stories of people messing up the o-ring seal - which may be what you have. If that is the case, you might be able to just replace that part and make sure it is seated properly. If it was serviced, which by its color it does look like it was, then Ramsey Volvo should fix it for free and pay you. They left you a potential bomb.
I'm sorry, Ramsey Volvo did FP a few years back not recently.


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shiloh51933
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Re: Fuel leaking from tank 2004 XC90

Post by shiloh51933 » Tue Feb 05, 2019 12:36 pm

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2004 XC90 T6 w/plastic fuel tank; fuel sending unit o-ring and is also the fuel pump o-ring.
It wouldn't make sense to go through all this trouble removing the middle row of seats and skip replacing the o-ring. The plastic tank uses a green o-ring and the metal tank uses a black o-ring. I used my VIN # to order mine directly from Volvo because I wanted it ASAP but you can easily check underneath your XC90 to see what you have.

I found some useful information using Google, turns there was a recall on some earlier years of the XC90 concerning the fuel pump. From 2003-2005 some XC90's were affected, it was about 130k that were eligible for this recall...I think it worth looking into.


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