We bought a used 2017 XC60 T6 R AWD in 2022 for our teens to drive. It had 116k on it when we bought it and was a single-owner vehicle with good service history/records. After buying it, I took it to a local Volvo specialist for the 120k service. In looking closer at that invoice, it does not indicate that the fuel system was checked. The last time the fuel system was checked may have been at the 40k service.
In July of 2023, the car ran out of gas and shut down as my teens pulled out of the high school parking lot. The gauge indicated a couple of bars as remaining fuel level. Not knowing or suspecting that it was out of gas, we had a local and trusted repair facility arrange to have it towed to their shop. The local shop “confirmed there is no fuel pressure” and the presence of a “low fuel pressure fault.” It “found good power and ground at the fuel pump and the relay is working.” Although they confirmed “two bars” on the fuel gauge, on a hunch, they put 5 gallons in and the car started right up. After discussing the issue with the shop, we agreed to just not let it get below ½ tank as our collective research showed that simply replacing the sending unit did not always correct this problem.
Around the beginning of this year, my younger teen and I were out driving it after she got her learner permit. We filled the tank and drove it for about 25 miles when it gave a gas cap error. Loosening and tightening did not help. Ultimately, we got a CEL for P0455. I purchased a new cap from a dealer and that seems to have ultimately resolved the gas cap code (returned a couple of times), but not the P0455.
Well, teens being teens, they let it get below ½ tank. I went to do them a favor and put gas in it before they went off to do some volunteering. It’s a good thing that I did it for them because it ran out of gas about 30 ft from the pump. It died after I made a right-hand turn as I entered the station. The car also died after a right-hand turn pulling out of the school lot – when it first died in 2023. An attendant helped me push it to the pump. It was showing 3 bars. I filled it, but it only took 14.5 gallons and it should have a capacity of 18.5 gallons according to the manual and Google.
It started right up after putting gas in it. I pulled the codes with my scanner and two additional codes were present – P00C6 and P008A. My simpleton internet research indicates that these are low fuel pressure codes. I cleared the codes to see what comes back on – presumably the P0455.
So, my layperson summary is that it dies as if out of fuel even though fuel may be present and it is indicating a large evap leak. Could these all be related and perhaps point to a solution?
This is all above my pay grade and I will certainly take it to a professional. But, I am hesitant to return to the first Volvo specialist and want to have as much of this solved as possible before I start incurring repair fees. I have read a few threads on vacuum/evap testing, smoke testing, etc. I also read a thread that a fuel filter could be a culprit and I am willing to check/replace filters (I do that on my diesel F250). I have also read some generic posts about sending units/pumps that might also be the cause of the P0455 code. Some posts also suggest that a transfer line from different sides of the saddle tank might be to blame (loose or not connected). The initial problem with the incorrect fuel level indicator spooked me a bit as those are expensive fixes and don’t always resolve the problem. Since it appears to have “run out” of fuel today even though it only took 14.5 gallons, I am suspicious of something more than the sending unit. Again, I am looking to narrow in on the more probable causes/fixes. I am willing to spend to fix this, but need to spend wisely.
Less relevant factors include the following. I am in a suburb of Phoenix and we park it outside on a slight decline from our house to the street. Most of the time the car is parked so that the front is towards the house – parked uphill (again, not much significant incline). Although rodents could be a suspicion on any vehicle, this car is driven daily and we don’t live in a neighborhood that would lend to that suspicion. The oil was recently changed (before these issues) and other maintenance (tires, alignment) are done regularly. On a side note, I also need to have this fixed by September as it will be due for emissions/registration then.
Thanks in advance.