I have an 85 DL. I had the intank fuel pump replaced because it sounded like their was a robot in my back seat. After getting the pump replaced I now notice the smell of gas inside the car. I thought nothing of it until I filled up the tank and had about a gallon of gas leak onto the pavement. Now I dont fill the tank up at all but it is beginning to bother me that I can not get a full tank of gas and my car smells after a trip to the petrol station. What should I do? Any suggestions? Any specific part need to be replaced?

It sounds as though you had the work done at a garage... as in paid to have it done by a professional. Well it sounds like they screwed up. They should fix it if they did something to make it leak fuel. Be nice but be firm in your conviction that they should fix it on their dime unless they can convince you it was not their fault.

Randy

If you live in a place where salt is used on the road, I would say that the fuel return line is probably where the leak is. The metal return line runs under the under the driver side and up along the left rear wheel well and over the years will rot from road salt. Since the line is not under pressure, all that you need to do is go down to your local auto parts store, get some rubber tubing (made specifically for gas lines), cut out the piece of return line that is rotted and connect it with the new rubber line. I had to do this for my 245 last fall and it hasn't leaked since. good luck!

Unfortunately, when you get someone else to work on your car you have to trust that they'll put things back together without breaking anything.

If it leaks when you fill up, then the problem is in the upper part of the tank.
It may be that the bung nut holding the pump-sender isn't tight or you have a broken hose. Lift the trunk carpet and remove the plate that'll give you access to the top of the tank where the pump is. Check for broken lines.

You can also crawl under the car and look for an area where gas has washed off undercoating. It may be due to a tank leak.

On the other hand since you are continuously smelling fuel you may have a leak in the lines. As your's is an old car, check for seepage through the fuel lines from front to back. Ie. there may be rust through and the line will be damp.
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1980 245 Canadian B21A with SU carb and M46 trans

The smell is only noticable when I fill up so this confuses me even more. The bung nut sounds suspicious but Im not sure. I dont know if the lines could be that rotten since the car has never left Florida.

There is (or should be) a rubber ring gasket that fits in a groove on the top of the fuel tank, under the top plate of the sender unit. When they put the ring nut back on and tightened it, they may have buggered up this gasket (or forgotten to install it). On the other hand, they may have twisted a old fuel line to the point that it leaks a bit, or maybe just didn't get one of the hose clamps back on tightly. Where are you in Florida? If you're in or near the Tampa Bay area, bring it by; I'll be happy to take a look.
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Mike W., '79 242GT (project car), '85 245DL (daily driver 1), '87 245 DL (daily driver 2), '90 244DL (project car), '91 744T (daily driver 3), '92 245DL (parts car), '94 944T (wifemobile), Largo, FL

Thanks Mike. I am about 20 miles west of Orlando. I will probably call the shop tomorrow to see what they can do. I am very surprised that this continues to happen because this particular shop has been servicing Volvos for almost 30 years. Do you know of any other good shops?