OK I've had the evap small leak code for a while now and I wanted to get it fixed. Its at the dealer and they replaced the filter and evap purge valve still has a small leak. so they smoke test it and find the leak coming from the top of the gas tank. The dealer tells me it could be from a cracked fuel pump, that they crack and leak from two spots the top where the wires go, and the dip where the wires are run. Did anybody have this problem before and how could this leak from these two sopts. I looked at a aftermarket pump and can't see where it could leak . Thanks for your responce 2000 2.4 C70 turbo. Im into them so far for 800 bucks pending........

More research, it's not the pump that's the problem it's the fuel pump assembly that's replaced. the O ring underneath leaks wears and the electrical connection on top cracks. U can see the assembly on eEuroparts under fuel delivery. hope this clears up some confusion......

OK Klaus volvo says its the pump thats the source of the smoke. I ask are they 100 percent sure they say yes even through I wont pay for another smoke test (108.00 bucks) to confirm it. The reason is the pumps crack at the electrical connection and the o ring on the top of the pump goes bad and air escapes through the top. ( thus the po455 ) My bill for all of this is around 800 bucks. I'll be leaving with the car still with the code and the problem they want another 800 bucks to replace the pump. This is why sites like this are so IMPORTANT you guys help people so this kind of thing don't happen. This is why you post your stuff, now I'll lick to learn how to post pics on this site so I can bring you the conclusion of this problem thanks Joe.......

What's nice about the P0455 is that when the leak is fixed, the code goes away immediately upon next engine start. At least for me it did.
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My name is Klaus and I am a V♂lv♂holic

Ok this is from the dealer. Seal eroded exposed wires from gas leak. po455 still present from possible leak. I've looked at this job with pics from this site and don't see how the wires could be exposed. unless the leak got to wires outside the pump. Could I just need seals on the pump side and sender unit fix the exposed wires and be done with this Imat 1000 bucks please advise thank you Joe......

Your dealer is not addressing your problem, but inventing new ways to pay for a Cancun vacation. The fuel pump and sender are 2 different parts on an 850, and if the pump is original, it will not leak. Period. As for smoke coming out of the pump, that is just hogwash.

Too bad it is Saturday, but Email Volvo anyway:
http://www.volvocars.com/us/footer/contactus/pages/default.aspx

and follow up with a phone conversation on Monday. The people are friendly and are not part of the dealership, so speak nicely. Volvo needs to be aware of inept dealers and mechanics.

Your 'leak' should just be a cracked hose or a bad purge valve. Neither are expensive or hard to replace. The dealer should also have told you the specific Volvo code for the check engine light. And ask for all of the old parts to be given to you.
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My name is Klaus and I am a V♂lv♂holic

Ok I went and took a look at the problem. they went into the trunk and removed the access panel to the fuel pump (164.00 1 1/2 hr labor for that) There is a small wet spot on top but it looks like a part time leak not major. the two wires (white and Red) look like insulation was eaten away by some gas, but not bad enough to get upset about. when they told me about the po455 code the first thing they do is change the filter and valve and then go from there. I asked for another smoke test with the cover off to to see if thats the leak but they want another 108.00 bucks to do that. If you do a smoke test of the evap from under the hood would the smoke make it all the way through the charcol canister to the gas tank to show a leak???? Im going to get the car out of there and fix this myself i can't afford this anymore I'll never go back they'll never see me again,But i bet they don't care. thanks joe...

That kind of dealer doesn't car if you never go back, that is why a letter to Volvo would be more satisfying. Scan your bill and include it with your email.

Now, if the liquid around the pump is gasoline, that is not good. Stop at an autoparts store and get some petrol proof sealant that doesn't act like glue. Use the handles on a pair of pliers to stick in the plastic nut and unscrew it. Clean up the top of the tank, add a small amount of sealant, and screw the nut back on. Dry the wires. I like to drip on some hot glue on the wires, the plastic is flexible and will keep the wires from touching each other.

There are several methods of making a smoke bomb. Do a search here and Google for a simple method that uses a 2L coke bottle, and have some fun!
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My name is Klaus and I am a V♂lv♂holic

The dealer charged $164 to remove the 9 nuts that hold the pump and sender covers?
And said that a small gasoline leak is nothing to worry about.
Insulation stripped off wires that are close to this gasoline leak shouldn't be a problem?

Sorry, I'm beginning to think that this story is hogwash.
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"Differences of opinions should be tolerated, but not if they're too different' - Sharon Craig

FWIW, my very similar '98 S70 kept coding out PO455....turned out to the "j hose" back near the gas tank had cracked...$20 at my local euro parts house, and 1/2 hr on my back in driveway, problem solved...

The part that bothers me the most is i feel like i allowed this to happen. I just wanted this fixed and to go away. Im going to get the car back drop the tank replace the o ring on the pump and sender and inspect the hoses running to the tank I'll take pics and hopefuly post them. thanks again for your support my best to you I'll keep you posted.....

There is no need to drop the tank. What O ring? Is the sender leaking also?

If the pump or sender is leaking gasoline, there should be a considerable gasoline smell after parking the car. Remember, if the cap(s) is leaking at the pump or sender, it should only leak WHILE the tank is completely full.

The P0455 is a vacuum leak in the EVAP system, not a leak in the fuel delivery system. Check the vacuum lines close to the fuel filter.
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My name is Klaus and I am a V♂lv♂holic

Klaus remember the one thing that i did get out of them when they did the smoke test was they saw smoke coming out from around the right rear tire. there is a hose going from the canister to the fuel tank. isn't that the return next to the supply on top of the pump. im thinking thats the leak they might have seen. It would have been nice if they did that right.In calling them tomorrow I have to get the car out of there.

On my 95 850, I have a leak that appears to be a crack in the plastic material that houses the sender. I have some used parts at the ready just haven't replaced them yet. We don't fill up past 3/4 and there isn't any leak risk that way. I have not any codes or light as of yet.

Mark
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Hopelessly Volvoesque; 91 240, 95 850, 97 850

Frankly, the dealer's comments don't appear to say much of anything specific. Wires were eroded from a gas leak and there is still a possible leak? Huh? Why didn't they fix the leak? Especially after dinging you for a thousand bucks! There really aren't any replaceable seals on the pump. I suppose you could change the mounting seal, but I doubt that is the problem unless it was installed incorrectly at some time in the past.

Forget about finding photos of what it should look like at this time.
Instead, ask the dealer to show you exactly what is wrong and go from there.

Sorry, but it seems that there is a communications gap between the dealer, you and your explanation.
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"Differences of opinions should be tolerated, but not if they're too different' - Sharon Craig

I just replaced the fuel pump on our '95 854T yesterday.
There is no way that the pump could crack and let smoke out. Total BS.
Why are you paying for what is not fixed?
FWIW, I picked up a new Bosch fuel pump from eEuroparts for $89.
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"Differences of opinions should be tolerated, but not if they're too different' - Sharon Craig

This is supposed to be a Volvo dealer? Don't they know where the smoke is coming from? They just arbitrarily replaced an expensive part without first making sure they are at fault? The charcoal cannisters seldom fail.

Fuel pumps also don't leak like that. Granted the gasket material might have dried out and is now leaking, but a better guess is the air line next to the fuel tank filler line.

There are 2 inspection holes behind the rear seat. Repeating the smoke test with the covers off will show where the leak is. Do NOT replace the fuel pump.

And STOP throwing parts at it!!!
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My name is Klaus and I am a V♂lv♂holic