Help! 03 XC90 smells of fuel!
 

Hey all! I took my 2003 xc90 on a road trip from Oregon to Nevada and back, and it was misfiring on the way down, got the ignition coil replaced and had no other issues. Got it home and my husband put gas in it, and now it REEKS of fuel. Gas cap is fine, I don't see any residue underneath it, any ideas? It's the 5cyl, 144000 miles, tech said he didn't see any leaks at its last oil change. Figured I'd ask here before spending money on a diag.

check the top of the tank - probably the seal around the fuel pump/sending unit. Not sure how the pump is accessed on the 2003 XC90s but on many Volvos the pump is accessed via the interior (ie under the back seat or trunk panel) which explains how the smell gets into the cabin.

The weird thing is, we don't smell it inside the car, only outside. Recently it has started struggling to start, but it has no stored check engine codes. I'm hoping I can get it diagnosed soon.

have you inspected under the hood around the fuel pressure regulator and under the car by the tank to see if there's a weepy connector? GIven the start up issues, I'd be looking at the fuel pressure regulator - they have a diaphram in them that can tear and that allows the residual fuel pressure to bleed off when the car is sitting overnight - making for a hard cold start (pump needs time to build the pressure back up). Quick test is to pop the vacuum line off the pressure regulator - if fuel drips out, that's your culpret.

Have you looked at the top of the gas tank yet as well?