My 740's fuel return hose had cracked just where the rubber hose connects to the metal line on the bottom of the frame. Fuel would then drip into the upper drain hole, and then wooze down on the ground. Got a new line at parts store, slightly longer so I can trim it later as its ends harden.

Ummm. I think this reply was meant for a different thread 😀

Hi,

You might do better posting a new thread under AWD and using a specific tab for your car.
Even if they push the all tab under RWD I get all of those so if they do the same under AWD yours will pop up.
You can copy all your posts over and title things more specifically as you go to get better attention.

I wish I had a clue to where but I have never looked under the hoods of these cars very much because all I can see are plastic covers without much air space in between anything.
So with that, I understand your dilemma.

You will have to think that it’s in a small out of the way place as it couldn't be used for anything else.
On the 240s they didn’t get so cramped but it’s still under the front bumper and accessible.
It looks like a small coffee can size plastic canisters but today it can be a specially formed black plastic box. I suggest following hoses for a directional trail. They split and rot.
Please do not count on that working all that well, as another AWD poster, routinely talks or jokes about using some 12” Hemostats for retrievals 😬 or exploring 👀.

IMHO
This Comes from our populations being raised up in urban surroundings and those kinds of living spaces.
Having lots of things but it all looks neatly put away.
Eye appeal is sales appeal, as once told to me by a baker that’s one of the oldest professions next to prostitution.

The newest cars are conceptually enthralled with selling you something not really good for you, like pastries, but we smile anyways! 😋

Until maintenance or repairs are needed.

Phil
A 240 man with a smile of smugness for many years.😉

There is a tab here for the V90. It is under S90/V90. It is a RWD car. Basically an updated 960.
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Will I buy another Volvo??? We'll see....

I forgot to mention,
when I had the car at the shop getting the mounts replaced, I asked the mechanic if he could give me thoughts on a knock I was hearing during warmup. He told me the purge valve was making that noise. I don't think the purge valve was making the knock I was referring to, but none the less he recommended replacing the purge valve.

So, I guess what I am getting at, could a faulty purge valve in the engine compartment cause a gas smell by the filler?

I had a similar issue with my 945. In my case, it occurred right after a fillup. Or more exactly, it was strongest right after a fillup. Like you, I suspected something related to the EVAP system. This issue came with the car. Meaning, as the second owner, I never knew the car to not do this, the issue was inherited.

The solution was amazingly simple: the black rubber fuel filler neck seal (seals the cap end of the filler neck to the body of the car behind the hinged flap/cover) had come off the body of the car, leaving a tiny but obviously significant gap. As I inherited this issue, and this is my first car of this type, I didn't know any better. Refitting the seal to the body corrected the issue--it's never returned. Again. my issue presented differently, but I think it's a good place to start.



Not relevant, but the way I discovered the issue is that on that seal (still very visible, as it was butted up against the back of the quarter panel) had two impressions on the RHS, which seemed to line up with the round pegs (again, I'm bad with terms) that keeps the unhinged side of the flap against the inside of the filler recess, and is what keeps the filler door flush with the outside of the quarter panel. My filler door was slightly recessed, and I presumed there was some kind of rubber bumper that fit into the hole in those pegs. I had some extra of those small round bumpers that fit into the license plate bracket, so I put them in the gas door to make the door flush. In trying to find the correct part, I realized there appeared to not be any kind of bumper in those pegs. So I looked at my car more closely and finally realized the seal wasn't on properly. So if your fuel filler door doesn't look right, that could be another sign.

I hope this helps
-Wilson


EDIT: I was so eager to share my story, that I forgot about your p0442 code. My car is OBD1, and I had no code. However, I can't see how my issue would have triggered one. In your case, it seems more likely that it's something else. Perhaps a cracked bit of rubber in the vent near the tank, or possibly a bad fuel cap seal (that's not uncommon). I should clarify that my smell was inside the car, as well as outside. I'm glad I responded though. I'm guessing I'm not the only one who ever had my issue, assuming it happened on it's own, and not the oversight of some mechanic. I know on my car, all of that business is fairly accessible from under the car. I'm sure IRS makes it a little more complicated, but with a flashlight, telescopic mirror, and your favorite coffee or beer, it should be a straightforward job.

2nd EDIT: I'd obviously start with the filler cap seal. If it's dry or cracked, a new seal or cap is a no-brainer. On a different car, I couldn't buy the seal separate of the cap, and was still in the diagnosis stage. This car, a Honda DID present me with a CEL and emissions related code (but no smell, as I recall). Anyway, I removed the seal from the cap, and reinstalled it flipped over. Issue resolved, and I ended up never needing to replace it.

Some good and easy fix suggestions already elaborated here. Quickly:
1. Bad gas cap seal.
2. Years ago I had the plastic vent hose near the tank on my 90 240 crack and it was hard to find. If I recall correctly, I only had the gas odor after driving the car. Does your car have such a hose?
3. Check the rubber fuel filler neck for looseness per suggestion.

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Will I buy another Volvo??? We'll see....