Is the car on recirculate or fresh air? air from your aircon comes through the bottom of your front windscreen, make sure its clear and free of leaves or anything that can cause blockage to stop it from become damp inside the aircon ducts. if it is definately petrol fumes you may have an exhaust leaking from your engine bay, releasing the fumes into your cabin, that is the most common reason for petrol fumes in your aircon.
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Make sure the computer has been reset since changing the cap. Autozone, etc. will scan for free.
The smoke test should have caught the problem provided the shop looked at the gas tank too. There can be a problem in the electric solenoid valving for the canister which can be concealing a leak beyond the solenoid valving. If the solenoid is closing off the flow, then it can also close off the leak.
As for smelling gas, its the fumes which flow in these hoses, not raw gas. If the Vacuum system draws the fumes in, or if the leak is rearward, there is less of a chance of smelling the fumes. Rushing air from driving will dissipate many fumes.
from my experience, that is the smell of gasoline poorly burning at start up. getting into the cab that badly means that the climate control is sucking in fumes from the engine area, incredible this being a 2010. there also may be a leak at the heater core that warms up the cabin, basically coolant fluid fumes . definatly a warranty claim, something is very wrong here. pursue this with ford. battery leakage is total nonesense.
I also have a 2004 XC90 and a couple of months ago I had the exact same probelm... after multiple visits to my dealer's auto shop they figured out that it was the fuel pump. They replaced the fule pump and the smell disappeared. Good luck!