2004 S60 fuel leak

Rolvo

I have been suspect I could smell petrol for a while now, but definitely getting a smell of fuel only when I stop the car , around the driver side rear door is the strongest. Very faint smell inside the boot.
Makes no difference if tank is full or low.
Fuel consumption is normal.
No CEL as yet – will try for codes on the weekend as well
Was a faint smell when I first thought “that’s a odd smell” but I would say it is getting stronger – may be because I am knowing there is something but it soon goes away not long after stopping.

Will have a good look on the weekend.
I’m thinking fuel filter under car or a vent line on top of tank (nothing visible under car) – is there anything “known issues” or failings in cars of this era?

Cheers
Bruce

UNM

check if the fuel return line is leaking at the top of the fuel pump. The plastic casting can fail over time causing a slight leak.

You can do a quick visual inspection from under the car - if there are signs of fuel leakage coming from the top of the tank, near the front at the right hand side, it is likely coming from the fuel pump area.

You can remove the rear seat cushion and unbolt the inspection cover in the floor pan to verify. The seat is removed by pulling the front edge of it upwards sharply. I found it easier to use a lever next to each of the clips holding it in place as it is a tough bugger to remove. Just make sure the lever is right next to the clip - plastic retaining clip in the floor pan, U shaped metal bar is part of the seat cushion . 4x10mm nuts hold the inspection cover in place.

Once I could see the fuel pump, it was simply a matter of turning the engine on and looking for the source of the leak.

Feel free to ask me for more if you need it - I just did this last week and posted a thread. There are also you tube clips of it and also of how to change the fuel pump should that be necessary.

VolvoDeger

very common leaking at the top of fuel pump housing have hanged plenty of these

Rolvo

OK'sy dokey -confirmed leak on top of housing - looks to be a hairline crack and tends to leak slightly when running and more just after shut off.
I did some internet research - common problem - recall in USA in states where high temps are occurring (about 25 states), UK will replace cars with problems on certain VIN's - but nothing in Australia. Seams odd seeing we have exactly same fuel pump and tanks, obviously it is a known issue of faulty parts/materials by Volvo but little old Australia will do nothing . Not saying after 15 yrs I want a free pump - but if the part is known to be materially faulty, and leaking fuel is potentially a huge safety hazard - I'd say Volvo Australia are asleep at the wheel :) - Rant over.

So @VolvoDeger , if I was to get a replacement pump to you know if they upgraded the part or I would be getting the same item as originally fitted. Don't really want to put on a 2nd hand part as it would possibly have the same problem later.
@UNM, I checked out your thread - Identical problem - thanks for the heads up.

UNM

Rolvo;108849 wrote @UNM, I checked out your thread - Identical problem - thanks for the heads up.

FYI, there are a couple of really simple steps to getting the seat back out to replace the pump assembly .

You only need to remove one bolt near the right side rear door and to get to it you have to remove a clipped in seat side panel, which is held by two clips at the top and a hooked clip at the bottom. Release that top clip from inside the boot first. Some of the youtube vids make it look harder than it needs to be.

I'll grab a couple photos tomorrow if I get a chance. It saves possibly breaking the mountings when you remove it.

It's not just volvos that have this problem, peugeots also see it.

UNM

Hopefully this will work. I uploaded some photos of the seat side panel removal.

Edit: can't seem to embed links. Here is the direct link to photos:
https://goo.gl/photos/CuHqJDQiBKUNrtj27

First one is of the upper clip, which is accessed through the boot, pull the lining away just below the parcel shelf and that black clip you can reach is the main one holding it in place (simple latch that you push towards the outside of the car). Once that is released , there is a second one to worry about roughly 10cm lower and nearer to the outside edge. It latches against the protruding metal lip you can see in the secondphoto. I found it easiest to press the panel slightly towards the rear and towards the centre of the car so the edge of the catch releases from the metal lip. Don't force anything as it should release easily.

Once those two catches are out, you only need to remove the seat belt from the loop at the top and pull the seat edge panel upwards. Bingo. As you can see in the last two photos, there is a U shaped clip holding it in place at the bottom.

Removing the main seat back is then just a matter of releasing the one electrical connector and bolt exposed once this side panel is out. The seat then slides out easily (it's surprisingly heavy though).

Ping me if you need more info.