I have a 2011 XC60. Last summer I was having an issue with difficulty starting every once in awhile so I took it to the dealer thinking starter, alternator, etc. After a lot of "guessing", they told me it was my fuel pump. $1700 later, I still had the same problem. Fast forward 3 months, and I had a code for faulty fuel EVAP sensor which was $800 to replace. Four months after that, another EVAP sensor failure along with gas in the charcoal canister. Two weeks after that, the thing all but explodes. I was driving and lost fuel power completely before the car just shut off. At that point, I was out of state and had it towed to a different Volvo mechanic. This guy ended up telling me that when Volvo replaced the fuel pump, they damaged something inside the tank that caused the evaporative system to rupture, ultimately damaging everything else because gas was spewing in places it shouldn't. I had to have the entire fuel system replaced from the tank to gaskets and it was VERY expensive. I'm trying to gather some kind of info that can confirm what things can cause damage inside the fuel tank but I've had no success. Can anyone help me out? I want to seek reimbursement from the Volvo dealer that replaced the fuel pump for all of the related expenses and repairs since then. Is this a plausible theory, and are there any other things that can do damage inside the tank?
As a side note, I never overfill my tank, and I always use premium gasoline.