General: - Fuel Filter Housing Replacement

sam.orton · Jun 15th, 2012, 22:24

We had to have the AA called out the other day because the XC90 - D5, 2008, manual - stalled. Diesel was pouring out of the fuel filter.
Tried fitting a new fuel filter thinking it was o-ring failure, but turns out it's the crappy plastic housing unit that has a shredded thread.

So now i've got a new complete unit including filter from the local dealer - the car's pretty immobile at home, so dropping it in for them to sort isn't an option.
Fitting it looked simple, but getting to the bolts seems to be a nightmare. I've spent an hour underneath it tonight just confused.
Does anyone have any ideas, maybe an exploded diagram or something. I can see the bolt heads I need to undo using an angled mirror, but no easy way of getting to them.
Wondering if taking off the bracket that the housing connects to is feasible, but that seems to be pretty strongly connected to the fuel tank.

Any help would be very very appreciated.
cheers
sam

Pat1 · Jun 18th, 2012, 12:18

Just joined up in order to comment on this.

We had a 07 xc90 dropped here this morning with exactly the same fault. Ordered new housing and spoke to Volvo mechanic, He said that we have to drop the tank to gain access to 3 torx screws holding housing on.

Please let me know how you get on.

Pat.

Frosty · Jun 18th, 2012, 19:15

Seem to be becoming a bit of an issue these plastic housings, see my thread "URGENT help needed" from early June, ours went outside Le Mans 300km short of our holiday destination!!

Be interested to know what the UK dealer price is for these plus the labor to fit. I paid Euro 154 plus vat for the part plus filter plus labor so a nice Euro 380 all in!!

sam.orton · Jun 19th, 2012, 11:06

I managed to get a look at the vida instructions, and it does seem fairly simple thing to do.

You just:
1. unhook the brake pipes from the mountings on the tank straps,
2. apply a lifting table against the front part of the tank
3. remove the screw for the fuel heater pump and unhook it from the bracket
4. remove the screws for the tank straps at the front edge
5 lower the front part of the tank towards the exhaust pipe/prop shaft.

6. remove connectors & cables from filter
7. remove filter housing using TX25 wrench - two bolts accessed from above.

It does say don't try & replace the electrical cable with the new one - discard that (makes sense anyway), and make sure the tank is not more than 3/4 full.

Theory is good...I tried last night but struggled to get the tank down by myself as it's on the road and only had one trolley jack, not up on ramps etc.
So put a call into the father-in-law to come with another trolley jack tonight. Will let you know how I get on Pat.

Sam

sam.orton · Jun 21st, 2012, 09:24

Finally finished this off. Wasn't a difficult job in the end, but very awkward because the tank didn't drop the 4~5 inches I'd thought it would, more like 1~2 inches was all I could get.
So it took an hour of bruised fingers to get the old one off, then the same to get the new one on, but works fine now, and cost the price of a new unit from volvo, £106 total.
Sam

deeppockets · May 10th, 2017, 11:03

Just had the same experience, the filter housing split across the cover mounting threads causing diesel to spray out. Engine dead and diesel dumped over the road.

I am surprised that Volvo put a lot of effort into safety and reliability yet are happy to use a weak fuel line component that causes a significant fire hazard and castrophic failure of the car.

Fraze026 · Apr 7th, 2018, 10:36

Had the same thing.... part on the way, what does the electric bit do? I have read if you change the housing it needs an update that only the dealer can do as it cant be done with VIDA,

Did you guys connect the electric lead after changing to the new housing or leave it off? mines running on a temp bypass at the minute with no issues.

Confused... its just a housing for gods sake!

Borgi · Jun 20th, 2018, 20:39

Is an update required then if the housing is replaced?

I need to do mine☹

APinto · Apr 22nd, 2020, 08:22

Help please, mine just broke and needs replacing too, does it need a software update?

Cheers

S60D5-185 · Apr 22nd, 2020, 10:03

No, I do not believe that any update is required. Just fit a replacement and that is job done.

Jun 15th, 2012, 22:24	#1
sam.orton sam Last Online: Sep 14th, 2020 10:14 Join Date: May 2010 Location: Llanfairfechan	Fuel Filter Housing Replacement We had to have the AA called out the other day because the XC90 - D5, 2008, manual - stalled. Diesel was pouring out of the fuel filter. Tried fitting a new fuel filter thinking it was o-ring failure, but turns out it's the crappy plastic housing unit that has a shredded thread. So now i've got a new complete unit including filter from the local dealer - the car's pretty immobile at home, so dropping it in for them to sort isn't an option. Fitting it looked simple, but getting to the bolts seems to be a nightmare. I've spent an hour underneath it tonight just confused. Does anyone have any ideas, maybe an exploded diagram or something. I can see the bolt heads I need to undo using an angled mirror, but no easy way of getting to them. Wondering if taking off the bracket that the housing connects to is feasible, but that seems to be pretty strongly connected to the fuel tank. Any help would be very very appreciated. cheers sam

Jun 21st, 2012, 09:24	#5
sam.orton sam Last Online: Sep 14th, 2020 10:14 Join Date: May 2010 Location: Llanfairfechan	update... Finally finished this off. Wasn't a difficult job in the end, but very awkward because the tank didn't drop the 4~5 inches I'd thought it would, more like 1~2 inches was all I could get. So it took an hour of bruised fingers to get the old one off, then the same to get the new one on, but works fine now, and cost the price of a new unit from volvo, £106 total. Sam

May 10th, 2017, 11:03	#6
deeppockets New Member Last Online: Jul 5th, 2019 17:43 Join Date: Feb 2011 Location: Aylesbury	Just had the same experience, the filter housing split across the cover mounting threads causing diesel to spray out. Engine dead and diesel dumped over the road. I am surprised that Volvo put a lot of effort into safety and reliability yet are happy to use a weak fuel line component that causes a significant fire hazard and castrophic failure of the car. __________________ 2006 06 XC90 D5 Auto 1998 R Galaxy 2.3 Auto - dog car 1997 Mini MPI - project

Apr 22nd, 2020, 08:22	#9
APinto New Member Last Online: May 6th, 2020 08:33 Join Date: Apr 2020 Location: Feltham	Update? Help please, mine just broke and needs replacing too, does it need a software update? Cheers

Apr 22nd, 2020, 10:03	#10
S60D5-185 Me ? Surely Not! Last Online: Apr 5th, 2024 16:23 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	No, I do not believe that any update is required. Just fit a replacement and that is job done. __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic

Jun 18th, 2012, 12:18	#2
Pat1 New Member Last Online: May 27th, 2013 09:52 Join Date: Jun 2012 Location: Dublin	Just joined up in order to comment on this. We had a 07 xc90 dropped here this morning with exactly the same fault. Ordered new housing and spoke to Volvo mechanic, He said that we have to drop the tank to gain access to 3 torx screws holding housing on. Please let me know how you get on. Pat.

Jun 18th, 2012, 19:15	#3
Frosty Member Last Online: Mar 23rd, 2020 19:01 Join Date: Nov 2009 Location: Wivenhoe	Seem to be becoming a bit of an issue these plastic housings, see my thread "URGENT help needed" from early June, ours went outside Le Mans 300km short of our holiday destination!! Be interested to know what the UK dealer price is for these plus the labor to fit. I paid Euro 154 plus vat for the part plus filter plus labor so a nice Euro 380 all in!!

Jun 19th, 2012, 11:06	#4
sam.orton sam Last Online: Sep 14th, 2020 10:14 Join Date: May 2010 Location: Llanfairfechan	I managed to get a look at the vida instructions, and it does seem fairly simple thing to do. You just: 1. unhook the brake pipes from the mountings on the tank straps, 2. apply a lifting table against the front part of the tank 3. remove the screw for the fuel heater pump and unhook it from the bracket 4. remove the screws for the tank straps at the front edge 5 lower the front part of the tank towards the exhaust pipe/prop shaft. 6. remove connectors & cables from filter 7. remove filter housing using TX25 wrench - two bolts accessed from above. It does say don't try & replace the electrical cable with the new one - discard that (makes sense anyway), and make sure the tank is not more than 3/4 full. Theory is good...I tried last night but struggled to get the tank down by myself as it's on the road and only had one trolley jack, not up on ramps etc. So put a call into the father-in-law to come with another trolley jack tonight. Will let you know how I get on Pat. Sam

Apr 7th, 2018, 10:36	#7
Fraze026 New Member Last Online: Nov 12th, 2018 14:31 Join Date: Jul 2017 Location: Caersws	Had the same thing.... part on the way, what does the electric bit do? I have read if you change the housing it needs an update that only the dealer can do as it cant be done with VIDA, Did you guys connect the electric lead after changing to the new housing or leave it off? mines running on a temp bypass at the minute with no issues. Confused... its just a housing for gods sake!

Jun 20th, 2018, 20:39	#8
Borgi Junior Member Last Online: Yesterday 10:21 Join Date: Nov 2008 Location: Preston	Is an update required then if the housing is replaced? I need to do mine☹

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