My MY2004 Volvo S60 was smelling of petrol after each drive so I took it to the dealer. They found the petrol tank O-rings were perished and the fuel pump housing was cracked. They replaced the O-rings and the entire fuel pump assembly for $1,800.

The next time I went to fill with petrol it was almost impossible to fill up. The pump would stop a couple of seconds after starting even with a very slight pressure on the handle. It took about 10 minutes to get 30 litres in.

So, I took the S60 back to the dealer. Now they say it needs a new fuel filler neck (including pipe, vent, filter etc) which will cost $700 plus labour. I wonder why this problem only started after the previous work was done on the fuel tank.

Does anyone know why a car would be difficult to fill with petrol ? What could block the fuel filler pipe and prevent petrol going in ? Why would that need a replacement pipe ?

Thanks.