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What is your question?
Can overfilling the gas tank cause a leak in the system?

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Generally this wouldn't cause a leak. But no matter how it was caused it's very important to find out where the leak is occurring, then try to see if it may be related to overfilling. Have you had the source of the leak diagnosed yet?
Hi bretb- There is a fuel vapor return line that is passed through a canister of some sort, then sent back to the engine. This prevents some of the vapors from escaping- at least this is my layman understanding. There is a recall that began in Jan 2010 that states a fuel pump flange can go bad, but they say my vehicle is not part of that recall. I haven't taken the car to volvo yet, and couldn't find where ther fuel pump is located. Do you know if there are any special considerations in replacing a fuel pump on this vehicle? Thanks for taking the time to help-
Hey Mach3, You're correct about the vapor line, it goes to a charcoal canister that stores fuel vapors. those vapors are then drawn into the engine and burned when you're driving. The recall is for a leaking fuel pump flange. The fuel pump is inside the fuel tank and is accessed through an access cover under the back seat. The issue they were seeing was a fuel leak under that access cover. Do you need your fuel pump replaced?
thanks for your reply- I just got back in town today (didn't drive), and haven't addressed this yet. I tried to get to the fuel pump, but had trouble removing the back seat. I used to own a detailing business, and found it easier to shampoo and vacume the rear seat outside the vehicle- never had a problem. Any suggestions?
In theory it pulls straight up, but in reality they get stuck all the time. About 12 inches from the end, if you lift up the seat you'll see a metal bar going up into the seat, this is a u-shaped ring that the seat clips onto. If you pry near that area, you can get the seat to pop-up. Good luck!